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    You are here: Company information - KHS GmbH

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    Company information

    KHS GmbH

    Germany, Dortmund

    Brau Beviale Nürnberg 2014    ( Brau Beviale )

    Brau Beviale Visit KHS GmbH at Brau Beviale in Nürnberg, 11-13 November 2014, Hall 5, Booth 147
    29.12.2015   Lightweight PET bottles make a breakthrough in South America thanks to KHS Bottles & Shapes™    ( Company news )

    Company news -KHS lines for extremely lightweight PET bottles in Brazil
    -8.9 grams for 0.5-liter and 22 grams for 1.5-liter bottles
    -Água Mineral Santa Joana cuts material consumption

    Premiere of extremely lightweight PET bottles for still water in South America: thanks to Bottles & Shapes™ lightweighting expertise from KHS 0.5-liter PET bottles weighing just 8.9 grams and 1.5-liter PET containers at 22 grams are now available in Brazilian stores for the first time ever. The German systems provider of packaging and filling machinery has developed special bottle designs and preforms for both formats, making the PET bottles much lighter than the plastic bottles commonly found in South America while giving consumers the high degree of bottle stability they expect. Water bottler Água Mineral Santa Joana recently began filling its new, lightweight PET bottles and is now making considerable cost savings in both materials and energy.

    "The lightweight PET bottles developed by KHS mark the start of a switch to extremely lightweight bottles on the South American market," emphasizes Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH. To date, relatively heavy PET bottles have been commonly used to bottle beverages on the subcontinent. "With the expertise provided by KHS beverage producers can now cut down considerably on their use of resources in the long term." This applies to energy, personnel and space – and not just to simply saving on bottle material.

    Great savings potential through less use of material
    The new 0.5- and 1.5-liter PET bottles for still water weigh significantly less than the bottles usually found in South America. Here, a 0.5-liter PET bottle normally weighs 13 grams, with the 1.5-liter PET bottle notching up 26 grams on the scales. KHS clearly reduces these weights, with the new 0.5-liter PET receptacle weighing just 8.9 grams and the 1.5-liter PET container only 22 grams – a saving of 31.5% and 15.4% respectively.

    In both sizes of bottle material is specifically saved by the bottle thread being much lighter. This now weighs in at 1.9 grams only for bottles with a neck diameter of 26 mm. KHS also makes sizable material savings in the bottle body. "Despite this much lower use of resources our lightweight PET bottles still boast undiminished high stability," states Arne Wiese, product manager for Bottles & Shapes™. This refers to the processing of bottles on the line, storage, shipping and finally handling in store. Within its Bottles & Shapes™ program KHS has redeveloped the lightweight PET bottles according to design specifications while taking the special requirements of the established Brazilian beverage producer into account.

    "Around 70% of the manufacturing costs for a PET bottle are attributable to the material used. Beverage producers can therefore considerably cut their costs by reducing the amount of materials consumed," explains Wiese. For example, with an annual production capacity of 300 million 1.5-liter PET bottles and a reduction of four grams in the packaging weight the potential saving amounts to up to €1.8 million – €450,000 per year for each gram saved.

    Light PET bottles in store in northeastern Brazil
    Água Mineral Santa Joana recently began filling its still water into lightweight PET bottles and selling them in northeastern Brazil. The company produces its bottles on an InnoPET Blomax 12 S machine which outputs up to 27,000 0.5-liter and up to 26,400 1.5-liter PET bottles per hour.

    "Europe and the USA are a big step ahead of South America when it comes to lightweight PET bottles. However, we see great potential here for boosting efficiency and providing sustainable PET bottling systems," says Niemeyer. The Água Mineral Santa Joana project confirms this assessment; KHS has already received a number of further inquiries for lightweight PET developments from the South American continent.
    (KHS GmbH)
    03.12.2015   More flexibility for keg fillers: the KHS Innokeg Transomat 6/1    ( Company news )

    Company news -Flexible system for keg washing and filling
    -Additional washing stage meets growing demand
    -Optimized filling head and redesigned fitting backwash

    In order to meet the growing demands made of keg washing, KHS GmbH has extended its established Innokeg Transomat series. Thanks to further optimization the flexible KHS Innokeg Transomat 6/1 inline machine for up to 100 kegs per hour and line provides hygienic filling with low CO2 and product consumption.

    With its additional washing station the KHS Innokeg Transomat 6/1 offers even more flexibility in keg hygiene. "With this we're meeting the demand of our customers for individual processes, such as longer steaming or additional rinsing stages," explains Hilmar Fickert, head of keg mechanical design engineering at KHS. The filling and packaging specialist from Dortmund, Germany, is actively pursuing the move towards customized washing specifications. Global trends, such as longer storage times and greater shipping distances, extended keg pool life cycles and more frequent changes of product, mean that the demands made of keg washing are also increasing in a number of ways. KHS is meeting this challenge and now making extended, flexible washing possible with an additional station for its established Transomat series. Whether filling or racking beer, wine, soft drinks, water, or juice, the individual stages in the process can be adapted to suit customer requirements.

    Other improvements which have a big impact can be found in the detail: if needed a new backwash cleans the keg fitting more thoroughly, for instance; the new media disc valve has been designed and the materials selected to enable an even longer service life; and the optimized filling system provides faster filling while remaining gentle to the product. "Our established Transomat 3/1 and 5/1 models also benefit from these modifications," says Fickert. "The Transomat 6/1 is particularly suitable when it comes to satisfying fastidious washing requirements and filling extremely demanding products in combination with top line performance."

    With their especially hygienic, standardized modular design existing Innokeg Transomat lines are installed, converted, extended or modernized in a very short time indeed. They are suitable for use as single machines or to supplement automatic keg lines for the medium capacity range. They are installed across one or two lanes (Mono/Duo series) or in groups. Monitor control with simple operator prompting enables direct access to all machine functions. The KHS Innokeg Transomat can also be flexibly adapted to process all market-standard, one-way containers, such as PETAINER kegs, KeyKegs, PolyKegs or EcoKegs.
    (KHS GmbH)
    30.11.2015   KHS delivers new filling line for big cans to Tsingtao Brewery in China    ( Company news )

    Company news -First delivery of a turnkey party can line to China
    -KHS Innokeg Multibloc F offers flexible filling
    -Tsingtao profits from low CO2 consumption

    KHS GmbH has delivered a turnkey filling line for big cans to China for the first time. To meet the growing demand on the Chinese market for these special beer containers in the long term, the system has been specially designed to cater for the requirements of customer Tsingtao Brewery Group.

    Photo: At Tsingtao, the KHS Innokeg Multibloc F keg filler fills the premium beer Augerta into five-liter cans.

    In Germany, only 10% of all beer sold goes to the consumer in cans. In China, the most heavily populated state in the world, this figure is already at around 18%. Big cans or party kegs in particular are proving increasingly popular both for private consumption and in some restaurants, where they can be ordered at the table by guests.

    Investment in a sustainable system
    So that the Tsingtao Brewery Group can meet the growing demand for these sizeable containers, it recently ordered a turnkey filling line for party cans from its long-term partner for filling systems, KHS GmbH. The Dortmund filling and packaging professional specially configured a fully automatic filling line with a capacity of up to 400 party cans per hour to cater to the needs of the Chinese market and Tsingtao Brewery. (Tsingtao is one of the most popular and traditional beer brands in China.) KHS developed a system equipped with four filling stations according to Tsingtao's request for modern technology and flexibility.

    Microbiologically safe filling in large cans
    The KHS Innokeg Multibloc F is a fully automatic filler which can be incorporated into any system concept without difficulty. Up to seven independently operating filling stations achieve a production capacity of up to 700 containers per hour. The spectrum here ranges from 3- to 10-liter cans and party kegs to large bottles. The system capacity can be expanded at will by installing parallel formations. The machine at Tsingtao fills premium Augerta beer into 5-liter cans with and without CO2 cartridges. In the future the line will also be able to fill 3-liter party cans.

    Further milestone in a successful partnership
    The Chinese brewery group already operates very successfully on KHS filling technology; the group's KHS machines fill between 36,000 and 72,000 cans per hour holding 330 and 500 milliliters. On the new line Tsingtao profits in particular from the low CO2 consumption of the filler of less than 720 grams per hectoliter.
    (KHS GmbH)
    26.11.2015   KHS wins World Beverage Innovation Award for lightweight 1-liter PET milk bottle     ( Company news )

    Company news -Lightweight 1-liter PET milk bottle receives award at BrauBeviale 2015
    -Solution for milk is prizewinner in two categories
    -Prestigious award for worldwide innovations in the beverage industry

    At this year's BrauBeviale in Nuremberg, KHS GmbH was presented with the World Beverage Innovation Award from British publisher FoodBev Media for its lightweight 1-liter PET milk bottle. The specialist for filling and packaging systems was victorious with this bottle in the following two categories: "Best Environmental Sustainability Initiative" and "Best Bottle in PET/PE". The new solution scores in particular thanks to its low weight and the related material savings. The prestigious prize is awarded for innovative designs and products as well as outstanding quality in the international brewing industry.

    "We are proud of this award. The award is testimony to our ongoing commitment in the field of innovative and sustainable product systems and solutions," says Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH. The lightweight 1-liter PET bottle for milk and mixed milk beverages was developed ready for the market and extensively tested at the Bottles & Shapes™ Center at KHS' site in Hamburg. As a handy alternative, the ultra-lightweight PET bottle offers many advantages versus the beverage carton.

    As with all packaging developments from the PET experts at KHS, the focus was on an exemplary balance between economy, market acceptance, and product quality for the new milk bottle. Material usage and energy consumption have been reduced considerably. With a thread diameter of 32 millimeters, the lightweight 1-liter PET milk bottle weighs a mere 20 grams. In comparison, PET bottles of the same size commonly found on the market generally tilt the scales at 22 grams. Thanks to material savings of two grams of PET per bottle, up to 140,000 euros per year can be saved based on a production of 50 million bottles.

    Maximum product safety and great marketing benefits

    The lightweight 1-liter PET bottle for milk and mixed milk beverages can be aseptically filled; it protects the product, reduces production costs, and is fully recyclable. Its FlipBase base reliably compensates the negative pressure created in the bottle during filling of the warm beverage. KHS offers two versions of the bottle with UV light barriers: a transparent bottle that is covered after filling with a protective sleeve on the one hand, and a white bottle with a reliable light guard made of titanium dioxide on the other. At the retail level, the newly developed bottle scores especially with its convincing handling. An intermittent rib structure ensures the desired easy-to-grip stability.

    The World Beverage Innovation Awards have been presented annually by British publisher FoodBev Media since 2003. The publisher presents awards to particularly innovative and high quality products and concepts from the international beverage industry in 26 different categories. These include categories such as design, packaging, sustainability, ingredients, and production processes.
    (KHS GmbH)
    02.11.2015   KHS stretch blow molder pays off after two years    ( Company news )

    Company news An investment well made: Herzog Mineralbrunnen Schäfer Betriebsgesellschaft mbH from Bochum, Germany, now makes its own PET bottles. The mineral water bottling plant made the decision to procure its own stretch blow molder together with KHS GmbH from Dortmund, also in Germany. Their acquisition will pay off in just two years – and Herzog Mineralbrunnen is already profiting from new capacities and a new liquidity.

    Photo: InnoPET Blomax Series IV stretch blow molder

    At the end of 2014 plant manager Gerd Stork had long been toying with the idea of no longer buying in ready-made PET bottles but producing them himself at the site in Bochum. There were several reasons for not doing so, however: there was not enough room for the new system, the effort involved in converting the engineering seemed too great and the existing production setup was established and running well. Stork needed a partner who was able to offer him advice and active support. He came across the right people quite by chance at BrauBeviale 2014 in Nuremberg. The man he found himself sitting next to at an evening event was Frank Fretwurst, head of Area Product Management for KHS Corpoplast GmbH. The two got talking and at the end of their conversation Fretwurst was also convinced that the Herzog bottling plant held certain potential for making savings. Stork and Fretwurst stayed in contact and KHS drew up a sample calculation for the plant manager. If he continued buying in his bottles as he had done for the past ten years, nothing would change. In the best case the price for the bottles would not increase. Fretwurst's alternative suggestion, however, was to purchase a KHS InnoPET Blomax Series IV stretch blow molder with extremely low operating costs. All Herzog Mineralbrunnen would have to do was buy in PET preforms which are much cheaper than finished bottles. These would then be manufactured on site.

    Stork was quickly convinced by the calculation. "The figures speak for themselves. In two years we'll have recovered the cost for the system," says the expert beverage industry process manager. The infrastructure also had to be right, however. He thus approached the company's in-house master electrician, Stefan Czerwinski. The following challenge presented itself: a new system would need an extension connected to the existing filling section by conveying segments. The KHS InnoPET Blomax Series IV may be extremely energy efficient but the site in Bochum did not have the necessary electrical power, meaning that new cables had to be laid and the transformer house expanded. As the two men planned and played through the new scenario, they continued to be convinced by the investment. The same went for managing directors Thomas and Ralf Schäfer after they had been presented with the idea. The savings made were worth the effort.

    A company with tradition
    The two managing directors are not the first Schäfers to head the company; Herzog Mineralbrunnen evolved from a beverage wholesalers founded in 1927 by Willi Schäfer. Stork has been with Herzog for 43 years now and has thus worked for several generations of the family. In 1978 the two sons Fritz and Willi Schäfer took over the management of what had become two company units, namely production and wholesale. The family business has now been chaired by Thomas and Ralf Schäfer since 1999. Today, 17 springs within a radius of one kilometer are in operation. In addition to the Lohberg brand Herzog Mineralbrunnen also markets Engelbert and Coronet mineral water and Herzog Life, the latter specially filled into elegant, blue glass bottles for the hospitality trade. Own brands commissioned by well-known commercial enterprises are also produced. Herzog is thus a traditional Bochum company which has grown over many years in the heart of the Ruhr region and is now a fixed feature on the local business landscape.

    Moving towards greater efficiency
    Stork again contacted KHS. The figures were right; he now wanted to see the machinery for himself. He first visited the KHS production shop in Hamburg and toured the factory and then went to Stuttgart. "We had a look at a stretch blow molder already in operation together with KHS," explains Stork. He stood in front of it for a long time, he remembers. "The Blomax just kept on running. Our decision was thus made."

    The order was placed with the filling and packaging specialist in March 2015, a few months after first meeting up at BrauBeviale. The first self-produced PET bottles were scheduled to be filled in Bochum in August. An extension covering an area of 128 m2 was erected with plenty of room for the compact KHS line. At the same time Czerwinski took care of the infrastructure. In total Herzog Mineralbrunnen invested around €1.6 million in their new engineering setup. To cover the time needed for conversion Stork had the plant produce in advance for a week to ensure a ready supply to customers. Things went as planned; on August 14, 2015, Herzog put the system into operation. Since then everything has been running round the clock without any problems.

    Energy efficiency and high performance
    The KHS InnoPET Blomax Series IV stretch blow molder turns PET preforms into bottles. The model in Bochum has a capacity of up to 13,500 bottles per hour which gives the medium-sized family business a capacity utilization of around 80%. The high-performance versions in the KHS InnoPET Blomax Series IV achieve outputs of up to 81,000 bottles an hour. The energy efficiency and compact design of the machine were major criteria in Herzog Mineralbrunnen's decision to invest. The quality of the bottles was also not allowed to suffer, of course, and these continue to have both optimum stability and be low in weight. "It's important that production doesn't stop. All of our lines run continuously," states Stork. Approximately 35% of all products leave the production line in PET, with the rest in glass. "The percentage of PET is growing, however," he says. The plant in Bochum fills about 29 to 30 million PET bottles a year.

    To meet the varying demands of their production operations, the heater on the KHS InnoPET Blomax Series IV can be used in combination with any type of transfer and blow molding equipment. Because the heater is modular, upgrades such as additional heating chambers can easily be installed at a later date. The stretch blow molder can also be adapted to cater for any extensions to the product portfolio whenever needed.

    The sustainability of his company's investment, coupled with the close cooperative partnership with KHS, prompts Stork to proclaim, "I'm so pleased!" The high degree of process stability and machine availability of the low-maintenance system allow him to look back on the past few weeks after commissioning with satisfaction. "In two years the system will have paid off. We have more line availability and are more flexible," he smiles. For family-run SME Herzog Mineralbrunnen, a chance meeting and a decisive management have resulted in an investment which has proved successful on all counts.
    (KHS GmbH)
    15.10.2015   BrauBeviale: KHS focuses on efficiency in energy and resources    ( Company news )

    Company news -Holistic systems for the beer and CSD sectors
    -Service portfolio with innovative solutions
    -Extension of the proven packaging portfolio

    At this year's BrauBeviale in Nuremberg, Germany, to be held from November 10–12, KHS GmbH will be focusing on the efficient use of energy and resources. The manufacturer of filling and packaging systems for the beverage, food and non-food industries will be presenting energy-efficient lines and single machines. KHS also attaches great value to the provision of extensive services, such as line optimization, designed to continuously improve the efficiency of all systems.

    "Our system expertise enables us to launch pioneering products and systems to market for practically all kinds of application," says Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH. The main target groups at the Nuremberg trade show are SMEs and the big players in the beer and CSD sector. Whether cleaning, filling, packaging or line management are required, KHS supports its customers with a full range of services. The portfolio includes various packages of measures aimed at boosting efficiency in the long term for more ecological and economical production.

    Three systems for greater efficiency
    Specifically for medium-sized breweries KHS will be introducing the Innopro Ecostab B (photo) which provides regenerative beer stabilization with polyvinylpolypyrrolidone or PVPP. The filter areas on this modular system are smaller than those of comparable systems; the machinery is also especially gentle on resources and takes up considerably less space. The Innopro Ecostab C is suitable for the fully automatic production of up to 900 hl of beer per hour. Both Innopro Ecostab machines require up to 70% less PVPP than standard systems.

    The KHS system for the pasteurization of beer, soda pop, non-carbonated beverages and juices with and without pulp is the Innopro KZE. Precisely configured to suit the beverages being processed, the flash pasteurizer reliably destroys microorganisms and inactivates enzymes.

    On the Innofill Glass Micro DPG beer, mixed beer beverages and soft drinks, for example, can be filled into glass bottles at a rate of up to 25,000 bottles per hour. Equipped with the tried-and-tested assemblies and components used on high-performance glass fillers, all processes are fully automated and documented and can be reproduced at all times.

    Flexible keg processing
    The Innokeg Transomat 6/1 is the logical extension of the successful Transomat series. The process cycles on this innovative system are configured for both PET and steel kegs so that the machine yields optimum consumption values at a maximum line capacity of up to 100 kegs per hour and line. Regarding one-way kegging systems for beer and soft drinks KHS will have its further developed Innokeg PETBoy F2 keg racker on display at the show. This easy-to-operate machine processes various sizes of one-way PETAINER® keg in parallel on two racking heads. KHS is also offering a control system with a microcontroller for the first time. The standardized, modular hardware setup permits extremely reliable, customized control and takes up very little space.

    KHS will be exhibiting its extended product portfolio of packaging systems at BrauBeviale. Alongside its proven variants, such as the FullyEnclosed FilmPack and wrap-around packer, KHS is building up its multipack systems. The packaging specialist will also be introducing its new DisplayTray for cans and glass and PET bottles. It combines material- and cost-saving manufacture with attractive and effective presentation of products at the point of sale.

    Transparency and fast information
    In system management KHS is making a clear further move towards Industry 4.0; using the KHS everywhere app for iOS it is possible to call up the status of filling and packaging systems and individual machines at all times from anywhere around the world. The app communicates with all KHS lines and machines which are equipped with the new ClearLine HMI machine operating system.
    (KHS GmbH)
    25.08.2015   MARTENS Brouwerij brings Direct Print powered by KHS™ to market    ( Company news )

    Company news MARTENS Brouwerij based in Bocholt, Belgium, is launching a new brand of beer, ‘Dagschotel’, in coordination with a well-known group of Belgian TV sitcom actors, ‘F.C. Kampioenen’, to promote their upcoming movie ‘Jubilee Generale’.

    Photo: Talking bottles: MARTENS Brouwerij is launching a new brand of beer, ‘Dagschotel’, by the new printing method Direct Print Powered by KHS™.

    MARTENS injected some fun into the Dagschotel beer launch with digitally printed, premium quality PET bottles which come to life using a specially-designed F.C. Kampioenen beer smartphone application. With the app, F.C. Kampioenen characters printed on the bottles deliver special performances on the smartphone. When two bottles are brought together, the app brings to life a dialog between the characters – truly innovative and engaging – resulting in talking bottles.

    KHS and NMP Systems were key innovation partners for MARTENS both with Plasmax FreshSafe-PET® barrier coating for enhanced shelf life and premium beer focus and also with Direct Print Powered by KHS™. Direct Print is the first industrial-scale, digital printing process with low-migration UV cure inks to provide a food-safe solution for PET bottles.

    Phil Johnson from NMP Systems is excited about the Direct Print partnership with MARTENS and states that ‘the breakthrough technology of digital printing onto PET will enable beverage companies to change graphics within minutes instead of weeks, and create new forms of consumer experience in a world where everything is digital.’

    MARTENS Brouwerij mission statement ‘Every day our actions are defined by innovations in new technologies, processes and products’ is a perfect match for the close partnership with KHS, bringing new PET technologies such as FreshSafe-PET® and Direct Print into the world of beverages.
    (KHS GmbH)
    17.07.2015   Innovation award for KHS    ( Company news )

    Company news The KHS Group is heralded as one of the most innovative companies in Germany. On June 26 the international manufacturer of filling and packaging systems was rewarded for its successful innovation management at the 2015 German SME Summit [Deutscher Mittelstands-Summit] in Essen. The Top 100 Award was ceremoniously presented to the company during a festive event staged at the Colosseum Theater.

    Photo: Award mentor and well-known scientific journalist and TV presenter Ranga Yogeshwar (center) presents the Top 100 Award to Rolf Staab, head of KHS' Central Human Resources Division (right), and Dr. Peter Stelter, head of Technology Management for KHS (left).

    Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH, says, "We're very pleased to be named a top innovator of 2015. Innovation management enjoys a very high status at KHS and is of great importance for the success of our company group worldwide. Here, we always also rely on the ideas and commitment of our employees. I would like to voice my thanks to them for their large part in the award we've now won."

    Personnel development strengthens innovative power
    KHS believes it is very important to create a climate within the company which encourages innovation. Certain groups of employees, for instance, are able to use 10% of their work time to develop their own ideas. Inventor compensation and premiums act as additional incentives and are intended to encourage personnel to submit suggestions for improvements and innovations. The many topics covered by KHS campus, the further training platform for KHS employees, include personnel development courses on various innovation skills, such as seminars on creativity techniques and method expertise.

    KHS' international Engineer4Future trainee program also offers extensive schooling on products and projects and provides expertise designed to encourage thought and action across the corporate interfaces. The program is primarily geared towards engineering graduates with a PhD who have studied electrical engineering, mechanical engineering, information technology or similar subjects. Right from the start trainees gain international practical experience and an overall understanding across the departments for the demands made of KHS products and services, enabling them to build up a personal network. The key competence they gain during the course is a win/win situation for both sides: the trainees benefit and KHS' global competitiveness is increased. One of the program's current team projects deals with the development of a crowd sourcing concept destined to strengthen the management of knowledge, ideas and innovation throughout the company.

    Pioneering technological feats
    There are many examples of innovative power and innovative success to be found within the KHS Group. One major issue is lightweighting which has resulted in the design of pioneering beverage packaging. For instance, extremely lightweight PET bottles yield many benefits for both beverage producers and consumers with their optimum combination of economy, market acceptance and product quality. Another future-proof KHS innovation of note is the Nature MultiPack™ packaging system which has won the National German Sustainability Award. It does away with the need for film materials for beverage packs, thus enabling resources to be conserved and the amount of waste produced by consumers to be reduced in the long term.

    The company is also a technological pioneer with its KHS everywhere app. With it customers can retrieve information on the status of their filling and packaging lines or single machines on their smartphone – at any time and wherever they are in the world.
    (KHS GmbH)
    15.07.2015   KHS continues to grow in 2014    ( Company news )

    Company news -Service business expanded further
    -Countless innovations ready for market
    -Positive outlook for 2015

    KHS GmbH can look back on a very successful business year; in 2014 the manufacturer of filling and packaging systems for the beverage, food and non-food industries increased its sales by 5.8% to €1.08 billion. This was chiefly thanks to the expansion of its service business which the company is continuing to build up this year. With many innovations KHS also cemented its position as one of the market and technology leaders in the last year.

    „We're very pleased with how the last business year has gone and will continue to set course for innovation and growth," states Prof. Dr.-Ing. Matthias Niemeyer (photo), CEO of KHS GmbH. Business was especially good in Europe, with the company generating 35.3% of sales on its home continent (previous year: 32.8%). Other regions throughout the world also helped to promote growth at KHS, with the Middle East and Africa making up a 15.7% share of total sales, Asia and Pacific accounting for 23.8% and USA and Latin America for 25.2%. The total order entry was still at a high level of about €1.1 billion as of December 31, 2014.

    This renewed growth is not just attributable to KHS' project business but also to the fact that the systems manufacturer has expanded its service business. Thanks to the establishment of the new KHS World Logistics Center with its larger stock in Dortmund, Germany, KHS customers are now profiting from a higher availability of spare parts, faster logistics and shorter delivery times. The company also increased its warehousing capacities at other locations, such as Shanghai, in order to further optimize the international supply of spare parts. The new local presence of various KHS companies – KHS East Africa Ltd. in Kenya, KHS Panamericana SpA. in Chile and the service base in Dubai, to name but three – also increases worldwide coverage by KHS service engineers.

    Innovations cement market leadership
    With such a positive corporate development behind it KHS is continuing to strive towards its vision of becoming technological leader. One pioneering invention in the company portfolio is the world's lightest 0.5-liter PET bottle for highly carbonated beverages with a screw cap and a weight of just 10.9 grams. In mass production a reduction in weight and material of this magnitude soon yields a financial saving that goes into six figures (in €). This technology is being successively transfered to other segments, too; recently a 1-liter bottle for milk and mixed milk beverages weighing just 20 grams was readied for market. "This approach is of great interest to both existing and new customers, as our rising number of inquiries shows," explains Niemeyer.

    The high level of the research and development work being carried out by KHS is not least manifested in the company being presented with the 2014 German Packaging Award. The innovations to win the prize were the Direct Print Powered by KHSTM bottle printing process, currently at the prototype stage, and the sustainable Nature MultiPackTM packaging system. At the beginning of the year the KHS Innofill Glass bottling system again received the internationally coveted certificate for energy-efficient machines and systems from TÜV SÜD in Munich, Germany, in accordance with TÜV SÜD's energy and media efficiency standard. A further highlight of 2014 is the newly developed Plasmax+ coating technology process which gives beverages and liquid foods with a higher pH of 4.5 or more better long-term stability.

    Positive outlook for 2015
    KHS is expecting further growth with its future-oriented technologies in 2015. One of the projects KHS is forging ahead with is its Bottles & Shapes™ program, for instance. This holistic service for the development of bottle designs is aimed at increasing product quality and economy when bottling beverages. Bottles & Shapes™ was in especially great demand from KHS customers in 2014, echoed in the record growth in blow mold production of 25% compared to 2013. Other established systems, such as the Innofill Can DVD can filler with an output of 132,000 cans per hour, are also seen as growth factors for the future.
    (KHS GmbH)
    23.04.2015   KHS: much greater demand for PET consultancy    ( Company news )

    Company news -Customer demand for new bottle designs noticeably higher in 2014
    -Lightweight and special bottle designs at the forefront
    -Holistic consultancy program

    Photo: Packaging designer Claudia Schulte combines the specific properties of a PET bottle with high-quality design.

    The demand for packaging solutions in plastic is huge the world over. The market wants sustainable, energy-efficient products for ever more sophisticated designs and applications. It requires packaging which is gentle on materials, energy and the product yet can be individually tailored to the specific content and brand. Whether water or beer, milk or fruit juice, shampoo or detergent, every content makes specific demands of the packaging.

    Sophisticated solutions
    KHS provides optimum solutions which meet these complex specifications with its innovative Bottles & Shapes™ program. This all-round service covers the entire development process from the initial suggested designs through laboratory testing to the ready-to-produce bottle, optimizing both the material and energy consumption and the balance between product quality and economy for the PET bottle. All of the relevant aspects for the smooth application of the new bottle in the filling and packaging line are also taken into account from the beginning. This holistic service was particularly popular with customers in 2014, this mirrored in the record growth in blow mold production of 25% compared to 2013.
    From a marketing point of view new bottle designs with special shapes are an important distinguishing feature and a selling point for consumers. Optimized bottle designs also help companies to save on materials and thus costs and resources.
    "We always start with the desired end product. This means that we ask our customers which demands they make of their plastic bottles. We take these parameters and design the ideal solution as a sample. We then develop the blow mold, carry out intensive laboratory testing and finally manufacture on state-of-the-art production lines," explains Johannes Köstlin, director of Service at KHS Corpoplast.
    With its successful Bottles & Shapes™ program KHS can react to individual customer requirements quickly and flexibly to produce a newly developed, tested bottle in a short space of time.

    Benchmark in PET lightweighting
    Particular proof that the Bottles and Shapes™ program has potential is manifested in KHS' lightweight record for 2014, held by the lightest 0.5-liter PET bottle worldwide for highly carbonated beverages with a screw cap and a weight of just 10.9 grams. The required quality properties such as stability and top load have of course been retained. In mass production a reduction in weight and material of this magnitude soon yields a financial saving that goes into six figures (in €).

    KHS is expecting further growth through its Bottles & Shapes™ program in 2015. Not only new customers will be a determinative factor here, estimates Johannes Köstlin. "We're also optimizing the production processes at our existing customer sites to boost the efficiency of lines already in operation. We see great potential here, as our customers can make considerable material and energy savings with new technologies and mold designs and thus significantly lower their production costs."
    16.03.2015   KHS at NPE 2015 in Florida    ( Company news )

    Company news From March 23-27 KHS will be exhibiting at the largest trade show for plastics processing in Orlando, Florida, in the USA: NPE 2015. In North America KHS will be presenting innovative systems and services for the manufacture, filling and packing of plastic bottles.

    Bottles & Shapes™ program for premium packaging One focus of the trade show booth will be the Bottles & ShapesTM program from KHS Corpoplast, one of the world's leading providers of stretch blow molders for PET bottles. Through this program the company gives its customers advice and support throughout the entire production process - from the initial idea for the plastic container through its development to the market-ready bottle.

    In the close collaboration with a customer's marketing and technology departments economical, ecological and functional aspects are always a prime concern. These include the innovative Plasmax process whose barrier technology protects products against premature vitamin loss and ensures a pure, unadulterated taste and longer shelf lives. The aim of these joint development activities is to produce premium plastic packaging which satisfies the highest market requirements and quality demands.

    Pioneering and award-winning Direct Print Powered by KHSTM
    One of the featured innovations is the direct digital printing process for PET bottles. This is marketed by NMP Systems GmbH, a wholly-owned subsidiary of KHS GmbH. Direct Print technology leverages co-developed low-migration inks for PET, producing brilliant CMYK + white process decorations on PET bottles. By doing away with labeling material, new or amended designs can be quickly and flexibly adapted to meet market demands. Here, standard labels are a thing of the past, greatly reducing production and transportation costs and saving on natural raw materials. Digitally printed PET bottles are 100% recyclable.

    To the point with sustainable multipacks
    In addition to the direct digital printing process KHS will be presenting a revolutionary technology for multipacks in the form of the Nature MultiPack™, which is also marketed by NMP Systems GmbH. In this process dots of special adhesive are used to simply stick containers together, providing the beverage industry with a packaging system which is exemplary in its sustainability. Compared to packs wrapped in film the Nature MultiPackTM requires up to 85% less packaging material and saves up to 67% energy during production. For its pioneering overall concept, consisting of Direct Print Powered by KHSTM printing technology plus the Nature MultiPack™ packaging system, NMP Systems GmbH recently won the internationally coveted German Packaging Award 2014.

    The KHS trade show booth (number 26157) is in South Hall at the Orange County Convention Center, Orlando, Florida, USA.
    (KHS GmbH)
    16.02.2015   TÜV certificate for KHS glass filler    ( Company news )

    Company news KHS GmbH has again received the internationally coveted certificate for energy-efficient machines and systems from TÜV SÜD in Munich, Germany, in accordance with TÜV SÜD's energy and media efficiency standard. The certificate has been granted to the innovative KHS Innofill Glass filling system for the glass bottling of soft drinks and beer.

    An audit was carried out in the fall of 2014 prior to certification, with the result that KHS is further entitled to use the TÜV SÜD energy and media efficiency quality mark for its glass bottle filler. With the certificate, valid until November 30, 2017, TÜV SÜD has confirmed the high level of sustainability inherent in KHS filling machines thanks to their consistently low consumption of water and electricity. KHS had already received a TÜV SÜD certificate for its Innofill Glass filling system in 2011.

    The flexible filler is modular in design and offers high overall savings potentials regarding the amount of energy and media used. Extra resources can be saved in the production process at brewery operations by utilizing the Eco vacuum pump. This allows KHS to support its customers with its innovative, high-quality filling systems which help to considerably reduce production costs and create systems which are sustainable in the long term.

    Careful husbandry of resources and raw materials is of great importance to the KHS Group. Any means of boosting energy efficiency and using environmentally-friendly processes are consistently exploited. The successful environmental and energy management practiced by all of the German KHS factories is confirmed by international ISO 14001 (environmental management standard) and ISO 50001 (energy management standard) certification. In the future these standards are also to act as a guideline for KHS' international locations. Furthermore, KHS has won a number of awards under the ECOPROFIT program (ECOlogical PROject For Integrated environmental Technology). This project aims to promote the ecological and economical use of resources through the implementation of appropriate environmental measures.
    (KHS GmbH)
    19.11.2014   Directly printed PET bottles in Nature MultiPacksTM win German Packaging Award 2014    ( Company news )

    Company news Each year under the patronage of the German Ministry for Economy and Energy the German Packaging Award is presented to only the very best ideas and innovations in the packaging industry. This year a specialist jury of 16 selected nominees from a total of 230 submitted entries. One of the prizewinners for 2014 is NMP Systems GmbH, a wholly owned subsidiary of KHS GmbH, which convinced the expert team with its new Direct Print and Nature MultiPackTMdevelopments – both currently at the prototype stage and which won the award as an overall concept. In combination they produce a multipack where information is printed directly onto individual PET bottles bonded together by dots of adhesive, thus producing a packaging system which is not only completely new but also extremely sustainable.

    Brilliant print quality
    In the direct digital printing process PET bottles are decorated with non-migrating UV inks, thus doing away with the need to apply labels. The containers are printed with CMYK process inks, white and – if required – special colors with an optical resolution of 1,080 x 1,080 dpi. The result is a brilliant color image. The UV inks dry within milliseconds and have an outstanding adhesion, therefore perfectly retaining the quality of the decoration during further processing of the bottles on the line, shipping to the retail outlet and handling by the consumer. Extensive research has confirmed that KHS' direct digital printing process is completely safe for the printing of food packaging. The printed PET bottles are of course also bottle-to-bottle recyclable.

    Focus on flexibility, sustainability and cost reduction
    Companies which utilize the Direct Print process profit from a very high level of flexibility indeed, as the required print images can be transfered straight to the bottle. Compared to the classic labeling system the time to market intervals are much shorter. The system is also especially sustainable and cuts costs. Labeling materials and adhesive are now completely superfluous. At the same time no more logistics are needed for label procurement, thus reducing costs for logistics and also CO2 emissions. If we assume, for example, that a classic labeling machine applies 36,000 labels per hour on 220 days of the year in two-shift operation, around 60 metric tons of labeling materials plus the necessary adhesive can be saved when the Direct Print system is used.

    The two buzzwords "sustainability" and "cost reduction" are equally applicable to the newly developed Nature MultiPackTM. Here, PET bottles are simply bonded together by dots of specially developed adhesive which ensures very good pack stability. Consumers simply twist the individual bottles off from the rest of the pack. Compared to conventional multipacks, where containers are wrapped in film, it has been proved that the Nature MultiPackTM requires up to 85% less packaging material and saves up to 67% energy during production. The new packaging system can be applied not only to PET bottles but also to glass bottles and cans.

    Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH, says, "We've taken new paths with Direct Print and Nature MultiPackTM, giving our customers the chance to be innovative leaders on their markets. The German Packaging Award 2014 once again underlines the viability of these two systems for the future. We're very pleased that a team as highly qualified as the expert jury for the German Packaging Award has specifically voted for this new and sustainable packaging system."
    (KHS GmbH)
    07.10.2014   KHS compiles comprehensive innovation package    ( BrauBeviale 2014 )

    BrauBeviale 2014 At BrauBeviale 2014 KHS is again presenting a wide range of innovations and product improvements. The company is thereby demonstrating the consistent manner in which it pursues its vision of becoming first choice in technology and service. The particular focus of the trade show booth will be on filling, keg and decorating technology and KHS' comprehensive consulting and other services.

    Innofill Can DVD (photo) with major technological advances in oxygen pickup and CO2 consumption
    In the filling technology field KHS will be exhibiting an electronically controlled, volumetric filler for cans in the form of the Innofill Can DVD with a capacity of up to 120,000 cans/h. In doing so, KHS is setting a clear benchmark. The system is equally suitable for different products such as beer, mixed beer beverages, wine, sparkling wine, soft drinks and also water in beverage cans with capacities from 0.1 to 1 liter. If particularly sensitive beverages, such as mixed beer drinks or still water, are processed, the Innofill Can DVD can be installed in a special KHS sanitary room with filter units in the ceiling. Above all, key features of the innovative can filler are significantly improved technological values, which have been proven many times in practice, and its optimized hygienic design.
    The oxygen pickup when filling 0.5-liter cans of beer previously lay between 80 and 120 ppb and carbon dioxide consumption was approx. 800 to 1,000 grams per hectoliter. With the help of the CAN+ low-pressure purging process used in the Innofill Can DVD, the oxygen pickup can be reduced by up to 50% while the CO2 values remain constant. On the other hand, the CO2 consumption can be reduced by up to 30% while the oxygen content remains constant. It is also possible to reduce both oxygen pickup and CO2 consumption, thus matching the technological values perfectly to the particular beverages to be processed.
    With the Innofill Can DVD, the following design features, among others, illustrate the consistent use of hygienic design: the open design of the can feed and discharge conveyors; no front table; drives in the form of servomotors mounted in star columns or encased in stainless steel; star columns and filler carousel connected by means of cross pipes without flanges in which cables and pipes are also laid; filling valves which can be easily flanged to and removed from the valve support; media feed through hygienic pantograph joints.
    The particularly hygienic design of the system results in reduced cleaning times and increased maintenance intervals. The associated water, energy and cleaning media costs are minimized and system availability increased. Maintenance costs are also significantly reduced thanks to the absence of many mechanical drive connections.
    Another important feature of the innovative filling system is the centering bell guide, which is implemented here by means of expansion joints. This enables the mouth of the can to be sealed under aseptic conditions. For the first time permanent water lubrication of the filling valves is not required and is always included in the CIP and sterilization process. Also of great importance is the fact that the can seamer is connected using servo technology.

    Innokeg Combikeg fully upgraded
    The Innokeg Combikeg, which has been fully upgraded, will also be receiving a great deal of attention during BrauBeviale. The hallmark of the keg, washing and filling machine, with a capacity of up to 80 kegs/h, is its extremely compact design. The systems for washing the kegs inside and out and for racking them are integrated into one housing, as are the media tanks, controls and conveyors. The Innokeg Combikeg is based on the proven rotary principle which has been continuously developed by KHS for decades. The target group is small to medium-sized businesses in the brewing, soft drinks, mineral water, fruit juice and wine sectors. One of the features that has been optimized on the Innokeg Combikeg is the safety paneling. Doors are now only half-height. The reason for this is that this makes it easier to keep an eye on the valves and sensors. Faster responses are possible when required and the system availability increases. An additional caustic spray, the task of which is to remove the ink code on the keg fitting and on the keg shoulder, is incorporated into the exterior washer. New valves (seat valves with cup gasket) are used specially for the washing stations. They are extremely robust in design and withstand the severe conditions which are present due to the use of chemicals and steam. As before, cap diaphragm valves are used on the filling station. In this way, all treatment stations are optimized accordingly to satisfy the individual requirements. Another important aspect is that the rotor main drive in the Innokeg Combikeg is no longer pneumatic. Instead, use is made of a servomotor which ensures very soft acceleration and braking of the keg when changing stations. Among the kegs to benefit from this are the particularly sensitive slim kegs and Petainer kegs. As well as processing steel kegs with a capacity of between 10 and 58 liters, the Innokeg Combikeg traditionally also handles classic Petainer kegs with adapters. The machine is also outstandingly equipped for the new non-refillable keg from Petainer which is presented at the trade show for the first time.

    Direct Print – the revolutionary technology for direct digital printing
    Direct Print, the revolutionary technology for the direct digital printing of PET bottles, is the subject of a major forum to be held at the BrauBeviale trade show booth. The printing process uses only UV inks which have a low viscosity, dry in milliseconds, adhere very well to PET bottles, have a high opacity, can be overprinted and ensure a brilliant color image (optical resolution of the printed images: 1,080 x 1,080 pixels). Extensive studies confirm their unrestricted suitability for use with foodstuffs. Another important factor is that printed PET bottles are suitable for bottle-to-bottle recycling without restriction. A sample Direct Print printer will be on show at BrauBeviale which is primarily used when only a few bottles are to be printed for presentation purposes and the like.

    Bottles & Shapes service and consultancy portfolio provides added value right down the line
    KHS traditionally provides added value right down the line with its globally unique Bottles & Shapes service and consultancy portfolio for the design and development of premium plastic bottles. At BrauBeviale packaging designer Claudia Schulte will be showing interested visitors how the specific properties of a PET bottle can be successfully combined with high-quality design. This applies equally to the PET bottle and cap concept as well as to the appropriate bottle decoration which will be directly demonstrated at the trade show using the aforementioned example Direct Print printer. All development steps are carried out from a holistic perspective. The focus at all times is on economic, ecological and functional aspects of the packaging to an equal measure. Lightweighting to suit the application is one of the features to play an important part in this process. Finally, all known influences are simulated and applied to the virtual packaging. As an example, these also include the stress the plastic bottle is subjected to while being conveyed through the line and up to and including the palletizing process, and also later during onward shipment to the retail trade and points of sale.

    The new Plasmax+
    In connection with plastic bottle production and finishing Plasmax+ will also be arousing great interest at the trade show. Especially beverages and liquid foods with a higher pH will greatly profit from the recently developed Plasmax+ process. It is as safe and reliable as the standard Plasmax process but has a better long-term stability with higher pHs of 4.5 or more. Where the bottle material is subject to greater mechanical stress from high internal pressures, for example when filled with carbonated beverages, Plasmax+ has the better barrier effect. This therefore considerably extends the range of possible applications for Plasmax+. The new technology can also be retrofitted into existing InnoPET Plasmax machines.

    Hall 5, Booth 127
    (KHS GmbH)
    25.08.2014   The world's first company to promote the innovative KHS Plasmax technology to consumers    ( Company news )

    Company news Based in Adana in the southern part of the country, Doganay Gida is one of the leading manufacturers of fruit and vegetable drinks in Turkey. Doganay Gida just recently ordered three KHS aseptic lines at once. Two of the three lines are already running production and the third will go into operation before the beginning of the 2015 season. The special feature of all three lines is that each is equipped with an InnoPET Plasmax (photo). This machine coats the insides of all PET bottles with an ultra-thin layer of silicon oxide - pure glass. This coating provides the best possible quality protection for bottled beverages by specifically preventing the exchange of substances such as carbon dioxide, oxygen, and flavorings between the product and the packaging and environment. This increases what is known as the shelf-life, i.e. this special PET bottle treatment makes it possible to store products safely for longer periods. A decisive aspect with regard to sustainability is that these coated PET bottles can be fully recycled.
    According to Rafet Doganay, who owns the company jointly with his brother Remzi Doganay and who is responsible for sales and marketing, "Doganay Gida has pursued a strict quality policy since the company was founded. The KHS aseptic lines equipped with integrated Plasmax technology aid us in realizing this policy in every respect."

    Targeted advertising campaign for CAMPET = GlassPET captivates consumers
    It is interesting to note that Doganay Gida is the world's first beverage company to communicate the benefits of FreshSAFE PET Plasmax technology directly to consumers under the term CAMPET, the Turkish equivalent of GlassPET. And in a very impressive, easy-to-remember, and strategically sophisticated way at that. An initial one-week TV campaign in which the Doganay company deliberately did not appear, merely showed how difficult it sometimes is for consumers to decide between the glass and the PET bottle. In a second likewise one-week broadcast, the TV commercial intimated that it is no longer necessary to make the difficult choice between glass and PET now that what is known as the glass/PET bottle is available. It wasn't revealed until the third week that the so very desirable glass/PET bottles contain Doganay Gida's Limonata product.
    Parallel to this TV commercial Doganay Gida placed the film clips on YouTube. Within only a few weeks the company had already chalked up more 250,000 views.
    Rafet Doganay: "The response to our advertising campaign was outstanding. Although we expected a great amount of interest, we did not suspect just how captivated consumers would be by the glass/PET idea. This clearly underlines yet again our high quality standard. We are very satisfied."
    In addition to one InnoPET Plasmax machine each, each of the two KHS aseptic lines already in operation includes a Blomax Series IV stretch blow molder and in all instances an Innosept Asbofill ABF 711 aseptic linear filling machine. Besides an Innopack Kisters SP Basic shrink packer, the packaging area shared by the two lines includes a roll-fed Innoket 360 Duo labeler. Robot grouping and the Innopal PB1N palletizer comprise a further part of the line concept. Both lines run at a total capacity of up to 24,000 bottles per hour processing 0.25- and 1-liter size containers.

    KHS aseptic lines mean active future-proofing
    According to Remzi Doganay who is responsible for the Technology division: "The lines are running perfectly and were put into operation within a very short time. We are especially looking forward to using the third already ordered line - an Innosept Asbofill ASR - the new generation of KHS aseptic rotary machine technology which will enable us to run production at up to 36,000 bottles per hour. Because of the rapidly growing demand for our products, for us this effectively means active future-proofing."

    In addition to the Limonata mentioned above, Doganay Gida produces many other non-alcoholic beverages. The sales volume in 2013 totaled about 40 million liters. The company's flagship product yet ahead of Limonata is Salgam, a vegetable drink made from the juice of fermented red turnips. Doganay Gida's market share of the Salgam consumption in Turkey is currently close to 95%. The range of products includes not only orange juice, pomegranate syrup, and lemon juice but also various vinegar products. Doganay Gida also distributes its products beyond Turkey's border and is active in more than 30 countries on all continents.
    (KHS GmbH)
    21.08.2014   KHS optimizes the Innoket 360 roll-fed labeler series    ( Company news )

    Company news KHS has extended its Innoket 360 series of roll-fed labeling machines. The Innoket 360 and extremely compact Innoket 360 S (with an output of up to 50,000 PET bottles per hour) have now been joined by the Innoket 360 Duo which has two roll-fed labeling stations and a capacity of up to 60,000 non-returnable PET bottles an hour.
    All labelers in the Innoket 360 series have also been further optimized. Brand-new developments include a servomotor-driven reel stand and an intelligent sensor which controls label cutting, reacts very quickly to new requirements and can also do without cutting marks (as an option). The Innoket 360 in particular is now even more flexible thanks to the option of integrating an extra self-adhesive labeling station and/or a tamper-evident sleever.

    The roll-fed labelers operate with a double reel stand, with film being unraveled from one reel while the other is idle. When the reel comes to an end, the speed drops momentarily and the autosplicer attaches the end of the active reel to the beginning of the waiting reel. Operation then continues without interruption. A sensor-driven web edge control ensures that the labeling material always keeps to its allocated track.

    In the past, when the film web was unreeled a mechanical control unit was responsible for yielding the given tension for precise cutting on the labeling station. A servodrive is now employed here, considerably reducing the amount of force exerted on the film web – namely by around 80%. In turn, this boosts machine tolerance to fluctuating grades of label material, making the Innoket 360 series even more robust and even more reliable. Thinner film materials than those previously used can now also be processed.

    With the classic cutting mark sensor the new label length had to be taught in on every format changeover. This is no longer necessary. The new sensor reacts to the operator simply touching the product to be processed on screen, resulting in even faster changeovers and fewer sources of error. The optional use of a sensor which no longer needs a cutting mark is another novelty. It can detect precisely where a cut is to be made by studying the label's pixel array. Label ends no longer have to be glued over unattractive cutting marks. In this manner up to 10 mm of label can be saved per labeled bottle.

    The proven highlights of KHS' roll-fed labeling machines include the cutting unit equipped with self-sharpening cutters, the slip-free vacuum drum and the induction heater in the gluing drum. The Innoket 360 labeler series thus scores not only on process quality but also on ease of operation, short changeover, maintenance and cleaning times and, as a result, a high degree of machine efficiency.
    (KHS GmbH)
    01.08.2014   KHS line heater for even more PET bottle material savings    ( Company news )

    Company news The beverage industry wants ever lighter PET bottles which also remain stable and ensure the quality of their products. With its line heater KHS is taking another important step towards reducing bottle weights – while maintaining first-class bottle quality.
    The line heater is a module that is usually integrated into the rear heater area of a KHS stretch blow molder. On request the system can also be quickly retrofitted with little effort. All the necessary connections are provided and the relevant interfaces standardized.

    Energy-saving shortwave infrared radiation
    The InnoPET Blomax Series IV stretch blow molder uses near infrared (NIR) to heat preforms. Only shortwave infrared radiation with an especially high energy density is used. With NIR the heat penetration of the preform wall is extremely intense – a feature further enhanced by feeding the preform through a closed heating chamber with all-round reflection. This enables an ideal heating profile to be applied to the preforms while saving energy.
    During the controlled heating process the neck area of each preform is shielded. This is because this area may not be heated to prevent any possible deformation of the neck, enabling the PET bottles produced after the heat-up phase to be securely closed. As the neck area is so critical, there is an extremely temperature-sensitive zone directly below the support ring. This must be protected against heat towards the neck yet ideally heated with the utmost precision towards the preform body in order that the PET material in this area can be perfectly stretched. The use of the line heater makes exactly this possible.

    Precisely focused linear heat ray
    The line heater is integrated into a specially designed module which has a reflector. The module has a parabolic mirror which produces a defined, precisely adjustable ray of heat. This permits focused heating of the critical area beneath the support ring without affecting the sensitive neck area. In this way, the additionally heated PET material can now be transfered to the bottle body during the stretching process. This means that lighter preforms can be used in the manufacture of PET bottles. When the product is changed over, the line heater can be quickly and easily adjusted.

    Annual savings greatly exceed investment costs
    If we assume that on the line heater 0.5 grams more PET material per bottle body is used than was the case to date, at an annual production of 100 million bottles this means that approximately 50,000 kilograms less material in total is used. At an assumed PET price of €1.40 per kilogram €70,000 is saved each year. This amount is many times more than the cost of investment in a line heater.
    (KHS GmbH)
    15.07.2014   Light and right – pioneering position with user-friendly lightweighting    ( Company news )

    Company news KHS on market with world's lightest 0.5-liter PET bottle for highly carbonated beverages with screw cap

    With its 0.5-liter PET bottle with a screw cap for highly carbonated beverages KHS is setting new standards in lightweighting. The bottle weighs just 10.9 grams which on an international scale makes it the lightest PET container for heavily carbonated beverages of its kind and size currently on the market.
    The launch to market at the end of 2013 was preceded by extensive research and development activities which involved the tried-and-tested Bottles & Shapes program, a unique service and consultancy portfolio for the design and development of plastic bottles – always bearing the entire bottling line in mind.
    The project was initiated by a customer request to optimize the weight of the 12.5-gram bottle used to date to the maximum – without detriment to consumer handling. This also meant that one of the essential requirements was that the bottle be resealable.
    One of the key steps in the process was the reworking of the bottle thread; the new receptacle now has a 'streamlined' thread. Despite the singularly low use of materials KHS has managed to increase the stability of the recessed grip by modifying the bottle shape.
    During the Bottles & Shapes program all known influences were simulated and applied to the virtual packaging using finite element analysis. The development of prototypes was followed by the production of the first sample bottles on a laboratory machine. These were then thoroughly tested at the certified KHS lab to see if they met all given specifications. These included, for example, the stress the bottles are usually subjected to while being conveyed through the line, up to and including the palletizing process, and also during shipment to retailers and the point of sale. An initial practice run on the sample bottles provided by KHS yielded positive results and industrial manufacture began at the end of 2013. Consumer acceptance of the lightweight is high, not least thanks to the optimized haptics.
    If we assume that 100 million lightweight bottles are produced at a beverage plant per annum, at an average PET price of €1.30 per kilogram over €200,000 in costs are saved a year compared to the 12.5-gram version. And that's just in materials. At the same time the bottle consumes less energy in its production and CO2 emissions during shipping are reduced by the lower weight.
    Despite the fact that KHS currently holds a unique position on the market with its extremely light 0.5-liter PET bottle with a screw cap for highly carbonated beverages, research continues – and not just with a view to reducing materials even further.
    Arne Wiese, the Bottles & Shapes product manager at KHS Corpoplast, says, "We believe there's still a lot of potential here. In the future, too, we'll continue to study all aspects and consider the line suitability of every new bottle we design in accordance with our Bottles & Shapes concept. Our large, long-standing customer base proves time and again that here we're on the right track. We look for solutions which satisfy customer demands right down to the last detail and, as the most recent system for highly carbonated beverages described here shows, in an ideal world we even surpass these."
    (KHS GmbH)
    11.07.2014   Innopro Ecostab keeps its promises    ( Company news )

    Company news Olympic Brewery S.A., founded in Greece in 2010, is one which is profiting from a beer history that takes some beating – despite its relatively young age. The reason is that prior to its establishment the owners of the brewery procured the brand rights to the first brand beer in Greece: Fix. Fix was produced during the reign of King Otto, Greece's first monarch, and made by Fix Brewery in Athens and Thessaloníki up until 1982. When non-Greek brewery groups joined the market, Fix Brewery went bankrupt and the brand rights to Fix were transfered to the National Bank of Greece. At the beginning of 2000 Greek wine producer Kourtakis procured the rights to Fix and in 2009 sold them to the owners of what's now Olympic Brewery, namely Ioannis Chitos and brothers George and Elias Grekis.

    Picture: Konstantinos Agouridas, master brewer and production manager at Olympic Brewery, states, "All the benefits of the Innopro Ecostab KHS described to us prior to investment have fully materialized in practical use."

    With the brand rights newly secured the three proprietors saw more opportunities than risks and thus considerably expanded the production capacities at an old microbrewery in the town of Ritsona, around 70 km from Athens. In 2010, the year of its founding, Olympic Brewery sold 120,000 hectoliters of beer. In 2011 sales rose to 190,00 hectoliters, with figures continuing to spiral in the following years to 385,000 (2012) and 400,000 hectoliters (2013) – despite the Greek beer market displaying a marked downwards trend. In 2005 the consumption of beer per capita was 40 liters; this has since dropped to 32 liters.
    By instigating a successful brand policy and giving Fix a taste specially geared to the Greek palate the company profited, also benefiting from the fact that during the recent crisis the people of Greece showed a distinct favor for the consumption of Greek products. This has also helped to make Olympic Brewery number three among Greece's breweries (after the Athenian Brewery, which belongs to the Heineken Group, and Mythos Brewery, part of the Carlsberg Group) in such a short space of time.
    In 2012 the company's consistent growth in sales prompted the brewery to switch from the one-way process for tannin-side beer stabilization it had implemented to date to the regenerative beer stabilization method. Many alternatives were checked prior to investment. Konstantinos Agouridas, master brewer and production manager at Olympic Brewery, says, "During this process we quickly realized that the Innopro Ecostab gave us the best range of benefits. However, we were a bit wary about investing in this system as it was new and hardly used in practice." After having their Innopro Ecostab in operation for almost a year now, these doubts have completely disappeared. States Agouridas, "We now know that the Innopro Ecostab gives us just what KHS promised us." The following features are particularly important to Olympic Brewery: the compactness of the modular system which runs 24/7; very short setup times for system startup and shutdown; short switching times between different beer styles and thus minimized blending amounts when changing products; and an extremely low consumption of PVPP. Agouridas tells us more. "Before we put the Innopro Ecostab into operation, we budgeted with around €300,000 a year for the disposable, one-way PVPP we used. Our PVPP costs have now dropped to €10,000 per year. Based on this and other factors we're reckoning on a return on our investment in just two years." The Innopro Ecostab at Olympic Brewery stabilizes beer using three stabilizer modules with two columns apiece. Up to 300 hectoliters of beer can be stabilized per hour. With this, the brewery feels it is also best prepared for all large rises in sales in the future.
    (KHS GmbH)
    08.07.2014   KHS Group: very good incoming orders and successful development in business year 2013    ( Company news )

    Company news - Incoming orders increased by over 11% to €1.1 billion
    - Position as innovative trendsetter clearly underlined.

    Picture: Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH

    The KHS Group has been able to considerably strengthen its position in an extremely competitive and dynamic market environment. With a turnover of €1,017.8 million KHS was 3.9% up on its figure for the previous year and exceeded the million-euro mark for the first time. Incoming orders rose by 11.3% last year, clocking up a total of €1,131.5 million. Profit before taxes, which in 2012 was slightly in the red, increased to €10.6 million. Compared to 2011, this is an improvement of over €90 million.
    In 2103 KHS realized 32.8% of sales in Europe, 16.5% in the Middle East and Africa, 21.9% in the Asia/Pacific region and 28.8% in the USA and Latin America. KHS is the partner of choice for both big concerns and small and medium-sized enterprises, wherever they are in the world.

    Innovation as a market force
    On the markets KHS chiefly scored with its energy and resource-saving innovations for the sustainable economic success of its clients. Labeling and container dressing and new filling and packaging systems were the prime areas of development in 2013. At the leading international drinktec 2013 trade show KHS presented a spectacular array of new products, among them technology for the direct printing of PET bottles and the innovative Nature MultiPack packaging system, where PET bottles are turned into multipacks merely by the application of a special adhesive. These were two really disruptive innovations, as both systems enable significant savings in packaging material to be made, these marketed under the single umbrella of NMP Systems GmbH. With its new rotary aseptic machine KHS also launched a safe and reliable system for the bottling of sensitive beverages in the high-capacity range. Monitoring systems, such as the MES manufacturing execution system, were also further developed and the app-based KHS everywhere info system was introduced.

    Consistent customer orientation
    The conversions business was one of the mainstays of KHS Service in 2013, with no less than 947 conversions commissioned – a plus of 34.7% compared to 2012. Innovative systems like AirbackPlus for the cost-effective and sustainable manufacture of PET bottles also had an important role to play here. KHS also released a number of new service concepts – for example detailed consultancy prior to investment and service packages tailored to specific customer needs across the entire life cycle of their lines and machines. These are further important generators of business. KHS' vision, which the company is consistently pursuing, is to be first choice in technology and service.
    KHS' endeavor to act as an innovative trendsetter in the industry – with a clear focus on its customers – is thus mirrored by its successful international project business and very good order situation.

    Optimistic prognosis
    For the fiscal year 2014 the KHS Executive Management Board believes that sales and profits will again be well above the previous year’s level.
    Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH, says, "Our high capacity utilization, lively service business and the success of the Fit4Future program form the foundations of this prognosis. We believe that a growth of 4% for 2014 is quite realistic."
    (KHS GmbH)
    02.07.2014   KHS receives ISO 14001 and ISO 50001 certification    ( Company news )

    Company news Picture: Anke Fischer, CFO/CHRO for KHS GmbH

    Protection of the environment, sustainability in the use of natural resources and social responsibility are major corporate objectives for KHS GmbH and KHS Corpoplast GmbH. This greatly accommodates the wishes of customers in the beverage, food and non-food industries worldwide, as they often consider attaining these goals across their entire supplier chain and within their own companies to be part of their brand policy. Such customers therefore also attach great importance to certification which confirms that their suppliers are acting responsibly. It's for this reason that in 2011 KHS had its new Innofill Glass DRS/ZMS glass filler certified by Germany's TÜV SÜD as energy-efficient plant technology. The next machines to be certified according to TÜV SÜD's energy and media efficiency standard in 2012 were the InnoPET Blomax Series IV stretch blow molder with its AirbackPlus system and the gas shrink tunnel for packing machines.
    The company was certified according to ISO 9001, the quality management standard, as early as in 1995. In 2011 KHS was certified in keeping with OHSAS 18001 (the Occupational Health and Safety Assessment Series). With a currency in over 80 countries OHSAS 18001 is one of the best-known standards for occupational health and safety management systems in the world. Furthermore, in 2012 and 2013 KHS carried out ethical audits at various national and international production sites and was granted the appropriate certification. KHS customers can view the results of the KHS ethical audit on the Sedex database. Nine purchasing organizations in the beverage industry, among others, are now interlinked. At the beginning of 2014 the company was certified according to ISO 14001, the environmental management standard, and ISO 50001, the standard for energy management valid worldwide, for all of its German production sites.
    Prof. Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH, says, "The issue of sustainability is an important element in our vision of technology and service leadership. It shows that values such as environmental friendliness and social commitment play a very significant role for us. We're backing up our claims with certificates and the appropriate audits performed by neutral experts to also convince the public generally of our policies."
    Prior to being awarded ISO 14001 and ISO 50001 certification KHS set up a number of teams headed by the plant energy and environment officers at all of its German production sites. These teams analyzed the current situation at the individual factories, drew up a list of measures for improvement and subsequently implemented these measures. The key environmental management topics were optimized handling of hazardous materials, e.g. by substituting these with less dangerous substances, improved waste disposal and savings in water consumption. Special hazardous materials rooms were installed, for instance, and waste disposal areas reorganized so that waste can be more accurately separated. Improved energy management focused on minimizing the energy consumption of machines, heating and lights, among other devices. Examples of the energy-reducing measures introduced include using waste compressor heat to also heat the production shops, deploying frequency-controlled extractors in laser machining centers and replacing the air conditioner at the Dortmund computer center with a system with free cooling.
    Florian Lerche, head of Corporate Development at KHS GmbH, states, "It's always that number of small steps which results in success. Our job is to continuously question prevalent states in order to make permanent improvements. In our energy and environmental teams we work on key figures which reflect the energy and environmental management objectives we want to reach in the short, medium and long term."
    These goals are also precisely described in the KHS production manuals. Energy and environmental management are key pillars in production and ones which all plant personnel are fully trained to be aware of.
    Says Anke Fischer, CFO/CHRO for KHS GmbH, "What's essential for the further improvement of our standards is that KHS employees are more strongly sensitized to the issues of sustainability and the environment and that we all pull together. Our certification is an extremely important hallmark of quality for both our customers and our personnel. It convincingly underlines KHS' far-sighted commitment to sustainability and the protection of the environment. Another measure we're planning for the near future is the compilation of a KHS sustainability report."
    (KHS GmbH)
    20.05.2014   Pioneering position with KHS    ( Company news )

    Company news The Van Pur brewing company holds a pioneering position among Polish breweries. It's not only one of the first breweries in the country to invest in a line for the manufacture, filling and packaging of PET bottles; it's also the first company to have procured an InnoPET Plasmax 12D machine, giving it cutting-edge coating technology. Piotr Polanski, operations director at Van Pur, says, "There were two reasons for opting for the InnoPET Plasmax 12D. Firstly, with the internal Plasmax coating of PET bottles we can offer our customers top-quality beer in light and unbreakable containers. Secondly, we’ve invested in a system which is cost effective and energy efficient."
    The InnoPET Plasmax 12D coats the insides of PET bottles with an ultrathin layer of glass. This coating prevents the migration of carbon dioxide, oxygen and flavorings between the product and packaging as well as the environment, perfectly protecting even the most sensitive of beverages against loss of quality. Polanski states, "Our products in Plasmax-coated PET bottles have the same quality parameters as those bottled in glass. We're thus able to provide a minimum shelf life of eight months for our beer in light PET bottles, too."
    Van Pur attaches great importance to sustainability. It thus considers another advantage of the system to be that bottles coated with Plasmax are 100% recyclable in the bottle-to-bottle recycling process. In the meantime everyone who works at Van Pur is also enthusiastic about Plasmax technology and the protection of the product. After a blind tasting session of beer of the same original quality which had been bottled in both coated and uncoated PET containers and stored for three months, the employees reached a unanimous verdict, namely that "The difference in taste is vast. The beer in the Plasmax-coated PET bottles has kept its freshness and full taste."
    The new KHS PET line at Van Pur consists not just of an InnoPET Plasmax 12D machine but also includes an InnoPET Blomax Series IV stretch blow molder, an Innofill DVF PET filler, an Innoket SE labeler and Innopack Kisters packaging technology. Says Polanski, "We're very satisfied with KHS technology. About 90% of the technical equipment currently in operation at our brewery is therefore from KHS."
    Van Pur is the largest privately-run brewing company in Poland and number four among Poland's brewery groups. It currently produces four million hectoliters of beer a year at its five breweries which constitutes 10% of all beer produced in Poland. As the biggest beer exporter in Poland Van Pur is active in 50 countries, with almost 50% of its beer destined for export. The company believes that in addition to the can the PET bottle is an extremely sustainable type of packaging which also scores on handling and transportation.
    (KHS GmbH)
    13.05.2014   KHS with new Innopouch K-400 pouching machine for the food and non-food industries    ( Company news )

    Company news The Innopouch K-400 is available as an FS (fill and seal) or an FFS (form, fill and seal) machine. The FS machine is supplied with prefabricated pouches from a pouch magazine; the FFS machine, on the other hand, both makes and fills the pouches. As the FS version is modular, it can be later expanded at any time to include a pouch forming unit.
    The system makes or forms stand-up, flat and bottom gusset pouches from film laminate. It can run in both simplex (one pouch per machine cycle) and duplex (two pouches per machine cycle) operation. In simplex operation pouches can have a width of 125 to 400 mm and a height varying between 125 and 380 mm. In duplex operation the maximum pouch width is reduced to 200 mm. Pouches may weigh up to 2.3 kilograms. The Innopouch K-400 can run at up to 70 cycles a minute. New pouch formats and capacities can be realized at any time should these be required.
    The Innopouch K-400 is a horizontal pouching machine which operates cyclically, with a separate station for each stage in the pouch forming and filling processes. This enables the machine to operate with the utmost precision, resulting in outstanding pouch quality and appearance and top filling accuracies.
    The Innopouch K-400 can fill pouches with various dry products from chunky goods like herbal candies and dry food for animals to finely ground powders, such as baking powder or ground coffee. The standard version of the machine has four filling stations connected in series which can be added to as required. The dosing systems are always selected according to the product to be filled, with both volumetric systems, such as auger fillers, table feeders and sliding gate fillers, and gravimetric systems like multihead weighers possible.
    Of great importance is the fact that in the filler area the pouch is held in place by one pouch gripper on either side of it. The pouches are therefore conveyed by just one pair of grippers until they exit the machine; there are no transfers. Another aspect which ensures top positioning and filling accuracies is the linear servo drive technology incorporated into the machine. Each pouch gripper consists of a linear motor and can thus be positioned very accurately at the press of a button.
    Special attention was paid to the hygienic aspects of the Innopouch K-400 during its design development. Thanks to the open design, there are no mechanical components under the pouch grippers that have to be extensively cleaned. In the machine housing spacers are used in place of the usual rubber seals. The film dispenser is also fully enclosed. One possible option is to separate the pouch forming and filling areas by a pane. The frame of the Innopouch K-400 is made entirely of stainless steel, making the machine quick and easy to clean.
    On pouchers fitted with linear servo drive technology fast format changeovers are a given. In particular, what used to be time-consuming changeovers from simplex to duplex operation and vice versa have now been greatly simplified and shortened. Most format changeovers are made on the operator panel at the push of a button. For example, the grippers in the filler area can be adjusted to new pouch widths as quickly as they can be switched between simplex and duplex operation. The few settings that have to be made by hand include changing film reels or adjusting the film guides and sealing units. If service should be required at any time, there is also a remote maintenance facility for the Innopouch K-400.
    As a turnkey supplier KHS can also pack the pouches into cartons once they have been formed, filled and sealed. For this purpose it has intermittent or continuous side-loading cartoners available in its Innopack IMC/CMC series. KHS has various options in its portfolio for gentle carton palletizing in its wide range of column and articulated robots. Entire pouching lines can therefore be realized from a single source.
    (KHS GmbH)
    17.04.2014   Number two in two years    ( Company news )

    Company news Owner of the Georgian Beer Company Tsezar Chocheli built up his brewery on a greenfield site in just nine months, with the first bottle of beer rolling off the conveyor belt on April 4, 2012. In its first year of production the company turned over 200,000 hectoliters, with this figure rising to 320,000 hectoliters in 2013 and with 450,000 hectoliters – currently the brewery's maximum capacity – planned for 2014. Less than two years since its founding the Georgian Beer Company is now number two among the breweries of Georgia. This is quite an achievement – and one that takes some beating.

    Picture: A strong team: Tsezar Chocheli, owner of the Georgian Beer Company (center), Vasili Sulkhhanishvili, technical director at the Georgian Beer Company (left), and Oliver Schneider, head of Sales for Eastern Europe at KHS GmbH.

    KHS plant engineering has been part of the success story since the very beginning. It all started with an Innokeg Till CombiKeg. As soon as the company began production, a second large order was sent to KHS for a can filler with an upstream rinser and conveyors which were incorporated into an existing glass line at the end of 2012. A turnkey PET line was also ordered which went into operation as planned in March 2013. A second turnkey glass line is to help expand the brewery's capacity as of April 2014.
    Chocheli is very enthusiastic about his KHS machines. "We've had a lot of experience with KHS in a very short space of time and can safely say that the technological concept is just as good as the quality of the service. KHS is also a partner we trust. I can only stress time and again how thankful I am for each and every one of our KHS lines, for it's these which ensure our success. After all, we can only supply outstanding products if we use outstanding plant equipment to produce and bottle them."
    At present the Georgian Beer Company markets three brand beers. The bottom-fermented lager Zedazeni clocks up 50% of the company's total beer sales, with Khevsuruli, a brand beer made in full accordance with the traditional Georgian brewing process, and the premium German König Pilsner brand, brewed under license, accounting for 25% apiece. What's interesting is that the Georgian Beer Company is the first company in the world to be given permission to brew König Pilsner under license. Vasili Sulkhhanishvili, technical director for the Georgian Beer Company, says, "König Pilsner decided to enter into partnership with us primarily thanks to our high demands for quality and our use of ultramodern technical equipment. König also recognized the high growth potential the Georgian beer market holds."
    The pro capita consumption of beer in Georgia currently lies at 25 liters a year. By 2020 Chocheli is reckoning on this rising to 40 liters and in the medium to long term even believes an annual consumption per head of 60 liters to be feasible. Chocheli says, "With this we'd be at the level of consumption Georgia enjoyed before the fall of the Soviet Union."
    The Georgian Beer Company is also active in the soft drinks segment, selling five soda pops in the flavors pear, lemon, grape, tarragon and cream soda, some of which are available in a low-calorie version. It also recently launched the first energy drink to be made in Georgia to market: Wilder.
    (KHS GmbH)
    15.04.2014   Efes Ukraine invests in KHS turnkey glass line    ( Company news )

    Company news The first six months of 2013 saw the consumption of beer in Ukraine fall, with the brewing industry having to announce a drop in sales of 4.4% – with the exception of one brewery: Efes Ukraine. Here, the sale of beer actually rose by 12.2%! According to Vasilly Basmanov, technical director of Efes Ukraine, this two-figure growth in sales is destined to continue over the next few years. In order to perfectly cater for the calculated increase in demand for Efes beers in the future, too, the company recently raised its production capacity by 34% and invested in a KHS glass line which can process 60,000 0.5-liter bottles per hour.

    Picture: Managing the perfect four-shift operation of the KHS turnkey line together: Vasilly Basmanov, technical director of Efes Ukraine (center), Oliver Schneider, head of Sales for Eastern Europe, KHS GmbH (right), and Mikhail Meshubovsky, Sales Ukraine, KHS GmbH.

    The turnkey line is now running in four-shift operation. KHS delivered in the space of just five months and had the line up and running after a mere four weeks of installation. The acceptance test yielded a result of 92% in efficiency. The conveyors throughout the line are frequency controlled so that they can process the many different types of Efes bottle (from the bulbous barrel bottle to the standard beer bottle) with very short changeover times. Both new and returnable glass bottles are handled on the line. An Innopal AS1H depalletizes the new glass bottles and the manually stacked pallets of soiled containers. An Innoclean SE single-end bottle washer with a Triple-i-Drive system and energy-saving bottle carriers has a caustic immersion period of 14 minutes, thus giving even extremely dirty bottles a thorough clean. The line also features an Innofill DPG-ZMS filler with a bottle sealing system for crown corks, twist-off caps or ring pull tops, an Innoket KL 2080 cold glue labeler, an Innopack Kisters TSP Advanced tray shrink packer and an Innopal PB1HS palletizer with upstream inline robot grouping.
    Basmanov is delighted with KHS' performance. "We're extremely satisfied with our KHS turnkey line and the perfect interplay of the individual components on it. Basically, this line actively helps us to secure our future."
    Efes Ukraine has a share of around 8% on the Ukrainian beer market, placing it at number four on the list of top-selling brewery groups. The company has 13 brand beers in 42 sales units in its portfolio and supplies the economy, mainstream, premium and super premium segments.
    (KHS GmbH)
    04.03.2014   New Feedflow feed unit for reliable and gentle conveying of lightweight PET preforms    ( Company news )

    Company news For its Feedmax preform sorter and feed system KHS has now developed the new, horizontally arranged Feedflow feed module which also conveys very light preforms to the InnoPET Blomax stretch blow molder quickly and extremely gently. The maximum output is 84,000 preforms per hour.
    The preforms are fed into a preform silo with an optional silo lid to protect the preforms from foreign objects. For very sensitive products that have a higher hygiene requirement the Feedmax system can be fully enclosed. From the silo the preforms travel along an inclined conveyor to an interim conveyor which discharges into the preform sorter. At the end of the sorter the preforms are fed in one lane to a discharge rail or, depending on the application, onto the active, horizontal Feedflow conveying segment.
    The traditional discharge rail makes use of the force of gravity to generate the required accumulation pressure which keeps the preforms continuously moving towards the stretch blow molder. The preform weight and quality, infeed angle, surface properties of the discharge rail, temperature and humidity are all factors which influence reliable transportation and conveying speed. This complexity can pose a risk to the course of production and line availability.
    As opposed to the traditional infeed by discharge rail, the Feedflow method actively conveys the preforms along the horizontal feed segment in a targeted flow of air. The frequency-controlled blower motors on the Feedflow ensure a constant and reliable flow of materials to the blow molder. This also ensures a high permanent level of line availability.
    Thanks to active preform conveying the new Feedmax system with its integrated Feedflow preform feed is much more compact in size. This greatly improves accessibility and also makes the machine much easier to operate and service.
    The combined Feedmax/Feedflow feed system has a controller included in the blow molder. The KHS ClearLine HMI, which has won a number of awards for its excellent ergonomics, logical navigation and attractive design, controls the process centrally, reduces machine complexity and makes operating the entire setup a much simpler affair.
    (KHS GmbH)
    17.02.2014   The Czech Republic: Budweiser Budvar invests in new can filling line to meet growing at-home ...    ( )

    ... consumption trend

    Budweiser Budvar says it chose to invest in a new KHS can filling line following a recent shift in the nation’s beer market towards at-home beer consumption, reported on February 10.

    In 2013 around 40% of beer sold in the country was consumed in restaurants and bars, the beer brand says, compared with 50% in 2005, with keg, tank, vat and barrel sales declining.

    Budweiser Budvar is the No.4 brand in the Czech Republic behind Pilsner Urquell, Staropramen and Heineken – native industry average sales rose 1.5% in 2012, but the brand recorded 2% growth.

    According to a recent case study released by KHS, sales of Budweiser Budvar in PET and glass bottles now account for 70% of brand sales at home, followed by 25% in kegs, tanks, vats and barrels and the remaining 5% in cans, a figure that is rising.

    “To date we had our cans filled under license. However, as there’s been a distinct growth in the sale of canned beer, it’s now worth investing in our own canning line. Even if our can sales should stagnate, it’s still profitable,” Adam Brož, master brewer and director of production and technology at Budweiser Budvar said.

    The Czech brewer recently installed a new canning line from German supplier KHS (it already runs three glass lines made by the company and one keg line) with an output of up to 21,000 cans (330ml, 440ml, 500ml) per hour.

    Citing increasing demand for Budweiser Budvar both in the Czech Republic and in 58 export countries, Brož said constant line operation was crucial.
    08.01.2014   Amazing achievement    ( Company news )

    Company news Picture: Sébastien Lacout: "KHS has given us a customized system which fully meets our specifications and is now running at high efficiency, even though space is extremely limited. I think that's an amazing achievement!" Also pictured: Carmen Germann, head of KHS' Regional Center Southern Europe.

    Business before pleasure. This is also the motto at the bottling plant run by Coca-Cola Enterprises or CCE in Clamart, France. At the beginning of 2013 two outmoded PET lines, which filled 27,000 and 32,000 0.5-liter PET bottles per hour respectively, were dismantled and a new KHS turnkey line with an output of 60,000 0.5-liter PETs per hour installed and commissioned in a record time of just three months. Sébastien Lacout, production manager at CCE Clamart, says, "When the first PET bottles started rolling off our new line, we danced around the production shop with all the employees and suppliers who'd helped put up the machinery and had a huge party. That was something we'll all remember for a very long time!"
    The new PET line had to be fitted into the space left by the former 32,000-bph machine. There was a reason for this, namely that the CCE bottling plant in Clamart intends on expanding its production capacity in the future. However, there's no land left on site for development, meaning that the only solution was to integrate high-performance line technology that took up very little space into the existing premises. Lacout states, "KHS' achievement here was absolutely amazing. Despite there being very little room our new PET line is very easy to operate, has plenty of buffer areas and is extremely efficient. I think that this is one of the best PET filling and packaging lines in the CCE Group."
    So that the new line could be perfectly slotted into the appropriate gap, a virtual viewing of the proposed layout in 3D was crucial before deciding on the final design, believes Lacout. "The Clamart project team went to Bad Kreuznach in Germany for this purpose," explains Lacout, "where we studied the concept on the Powerwall in 3D together with those KHS employees responsible. It was great that we could have our suggested changes added to the presentation and immediately see what effect these would have. This gave the line design the necessary final polish."
    Clamart is one of five CCE bottling plants in France. It produces 18 million crates per year (an average crate at CCE contains 24 0.5-liter bottles and thus holds 12 liters of beverage) and is planning on expanding production to 28 million crates per year in the medium to long term. Around 50% of all beverages are filled into PET bottles, with a further 30% flowing into returnable glass bottles and 20% into bag-in-box packs. The carbonated soft drinks produced at Clamart are all destined for the French hospitality trade, including fast-food chains such as McDonald's.
    (KHS GmbH)
    06.01.2014   KHS turnkey lines a major success factor    ( Company news )

    Company news Picture: Kirk Richmond

    The Silver Springs Bottled Water Company in Florida is a fixed feature on the North American water market. Founded in 1991 by Karl and Margaret Richmond the company is now run by son Kane and is one of the biggest water suppliers to the retail trade, chiefly producing private labels for this channel of distribution. The Crossroads Beverage Group, opened in Pennsylvania in 2012, is based on the same business model and also belongs to the Richmond family. Crossroads' COO is Kirk Richmond, son of the founders of Silver Springs and Kane's brother. The family set up their new bottled water company because they realized that there was a big demand for bottled water in the northeast of the USA. Kirk Richmond tells us more. "We were getting more and more inquiries at Silver Springs from the northeast which was why we decided to take action in Pennsylvania and open a second water bottling plant."
    A site and buildings for the new company were found at the end of 2011 and on April 16, 2012, the company produced, filled and packaged its first PET bottle of water – on KHS machinery. Says Kirk Richmond, "We've had so much positive experience with KHS turnkey lines at Silver Springs that we wanted to benefit from this expertise right from the start of Crossroads. With one multifunctional KHS line outputting 36,000 PET bottles per hour and a second working at a rate of 72,000 0.5-liter bottles per hour we felt we were perfectly set up to best meet the requirements of retailers in this region." The demand for quality water from Crossroads was considerable from the very beginning – and much greater than the Richmonds could have possibly imagined. At the end of 2012 a third KHS turnkey line was thus ordered for Crossroads which is now already running at half of its full capacity. Like the other two lines the newest system consists of an InnoPET BloFill monoblock with an InnoPET Blomax Series IV stretch blow molder and Innofill NV filling system, an Innopack Kisters SP Advanced shrink packer and an Innopal PB1HS palletizer with an upstream, inline robot grouping. Kirk Richmond states, "We believe that one of the main reasons for our huge success is that we're strongly geared towards the customer, both at Silver Springs and at Crossroads. We don't just supply retailers with their own brands in standard PET bottles and shrink packs; we also give them plenty of advice which goes as far as providing them with a full design package for their bottles, labels and secondary packaging. We're already reckoning on selling 500 million bottles of water in 2013. In the medium to long term sales at Crossroads could even top those at Silver Springs."
    To this very day Kirk Richmond names KHS as one of the company's major success factors and is quite happy to pass on this advice. "I can only recommend that everybody goes for high-quality technical equipment right from the start of operations," he smiles, "for this always pays off in the end. To be more precise, to us KHS technology means product safety and reliability, delivering to deadlines and, as a result, a strong position on the market."
    (KHS GmbH)
    27.12.2013   Optimized KHS Innopack Kisters Primus SP shrink packer with many benefits    ( Company news )

    Company news The Innopack Kisters Primus SP operates at up to 35 cycles per minute, perfectly complementing the KHS range of Innopack Kisters shrink packers to include a low capacity machine.
    As in the other series Primus SP machines are also cube-shape in design. More space within the machine means that there is better access to the individual components. Generously proportioned sliding doors with polycarbonate panes give an excellent view of the inner workings of the shrink packer – even during production. The new construction has an open, hygienic design. Despite being extremely simple to operate, the shrink packer is still compact; with a length of 9,700 mm (including the shrink tunnel) and a width of 1,950 mm, it can also be easily integrated into existing lines.
    The Innopack Kisters Primus SP has also had an overhaul regarding its control technology, with the system now equipped with a Siemens S7 controller. The machine has a total of four drives with a main drive, tunnel drive, film reel drive and feed conveyor drive and identical servomotors are used for all function units.
    In the old Primus SP series it was usual to have the switch cabinet under the shrink tunnel construction. In warmer climates especially the standard ventilation and cooling equipment used for the switch cabinet often exceeded its limits and additional or larger air conditioning units had to be installed. This is now a thing of the past. A welded tubular frame is used as a support for the shrink tunnel, with the switch cabinet placed next to the machine and therefore readily accessible.
    The Innopack Kisters Primus SP processes many different types of container, from the plastic bottle through the glass container to the can. Products and film are conveyed extremely gently, with product-dependent wrapping curves and an electronically controlled curve speed profile giving optimum film wrapping results. The shrink tunnel area utilizes variable hot air nozzle equipment and can be fitted with an optional energy-saving package for energy savings of up to 20%.
    (KHS GmbH)
    17.12.2013    Benchmark: new high-performance KHS palletizer with low-level pack feed    ( Company news )

    Company news Picture: With the Innopal PB1NF KHS is giving the beverage, food and non-food industries a new, single-station palletizing machine with level compensation which processes up to 500 layers per hour and has a low-level pack feed. The reason this machine works so fast is that there is a cross conveyor built into the front end of the palletizer which can be opened.

    The reason this machine can work so fast compared to others is that there is a cross conveyor built into the front end of the palletizer which can be opened. A barrier construction is used in place of the previous integrated bar construction. This means that after placing the last layer onto the pallet the cross conveyor no longer has to be raised and wait there until the finished pallet has been discharged from the system, as has been the case to date. Instead, the cross conveyor can travel down to table level before and the new layer picked up during the change of pallet which considerably increases the palletizing speed.
    The Innopal PB1NF also has all the benefits associated with a low-level pack feed on palletizers. One of these is that unlike palletizers with a high infeed neither a platform nor inclined or spiral conveyors are needed which has the advantage of reducing investment costs and providing excellent accessibility and thus great ease of operation. Upstream of the Innopal PB1NF palletizer a KHS inline robot grouping can be used where two four-axis Innopal RK4 robots prepare the layers with the utmost precision. The big plus here is that pack manipulation elements, such as turning stations, are not needed. Besides cutting costs as a result, other definite benefits for the customer compared to conventional systems are extremely gentle pack handling, great flexibility, reduced space requirements, less maintenance and fast changeovers.

    The Innopal PB1NF has been primarily designed to palletize one-way packs. Whether you want your cans, plastic containers or glass bottles packed in film, cartons or trays, it's all doable. As the palletizer acts as what's called a pusher plate machine, if required returnable packs can also be processed, such as high and low-wall plastic crates. The Innopal PB1NF can cope with layer weights of up to 200 kg; the block height including the pallet may be a maximum of two meters and pallets can be up to 1.3 x 1.3 m in size.
    (KHS GmbH)
    06.12.2013   Private brewery Moritz Fiege invests in the Innofill Glass DRS-ZMS    ( Company news )

    Company news Picture: Hugo Fiege, who now runs the brewery in its fourth generation together with his brother Jürgen Fiege: "For us, investing in the KHS Innofill Glass DRS-ZMS filling system is another big step towards the future."

    The privately owned Moritz Fiege brewery is deeply rooted in the Ruhr area of Germany. Founded in 1878 the family business is now in its fourth generation and run by brothers Jürgen and Hugo Fiege. Whenever there's something happening in the Ruhr, Fiege are in on the act! Whether it's the Ruhr tent festival, the Bochum kulinarisch food event or ExtraSchicht, the region's 'long night' of industrial culture, quality Fiege beers are part of it. The brewery exercises a definite premium strategy with its products in keeping with the motto that "Top quality has its price." According to Hugo Fiege, this commits the brewery on all counts, meaning that only the very best filling and packaging technology is – and always has been – utilized in production, for example. This way of thinking is also illustrated (among other things) by the brewery recently investing in the KHS Innofill Glass DRS-ZMS filler. Says Hugo Fiege, "We're extremely satisfied with KHS technology which has also been employed in our packing and palletizing area and to rack kegs for many decades now."
    The benefits of the new filling system are summed up by Mark Zinkler, first master brewer at Privatbrauerei Moritz Fiege, to give it its full German title: "The system's hygienic design considerably reduces cleaning times, allowing us to save energy and water. Line availability has also increased. With this filling system we're still profiting from very low oxygen pickup in the product and can thus safeguard the high quality of our beer." Zinkler is also full of praise for the advantages of the KHS Eco+ vacuum pump system for pre-evacuation integrated into the filler which saves up to 99% of the amount of water previously used by the classic vacuum pump. It also functions without the use of classic coolants and always runs at its optimum operating point.
    The filling system has been perfectly integrated into the existing line using new KHS conveyors. The line resumed operation after about two weeks and has since been running at a higher level of efficiency than it used to. Private brewery Moritz Fiege was one of the first breweries to invest in the innovative Innofill Glass DRS-ZMS filling system, therefore enjoying a clear competitive advantage and again underlining its status as a pioneer.
    The success of the brewery thus far has been strongly molded by two groundbreaking decisions. The first was in 1926 when Moritz Fiege, owner of the brewery in its second generation, boldly decided to start brewing pilsner. With the brewing industry then largely given over to the production of export-style beer, this was something of a revolution. Another courageous decision, which has proved partly responsible for the company's present success, was taken in 2002 when almost all of the brewery's classic crown cork bottles were replaced by clip-lock bottles in the space of just 14 days. Hugo Fiege tells us more. "We do what the people in the Ruhr usually do: we just get on with it, making our own not inconsiderable contribution to what happens on the market."
    At the time of writing Privatbrauerei Moritz Fiege sells about 135,000 hectoliters of beer per year, 70% of which is attributable to pilsner. The company's product portfolio also includes Gründer, Bernstein, dark Schwarzbier, Altbier, wheat beer, the light beer Leichter Moritz, a shandy with and without alcohol, a Schwarzbier and cola mix and Charakter, a special-edition beer for 2013.
    (KHS GmbH)
    02.12.2013   Tradition meets innovation    ( Company news )

    Company news Picture: Dr. Marc Kusche, managing director of Wernesgrüner Brauerei: "Our new KHS line utilizes the latest plant engineering which meets our high demands for sustainable production on all counts."

    At over 575 years old Wernesgrüner Brauerei in the Vogtland is one of Germany's oldest breweries. An innovative returnable glass line from KHS now ensures that the traditional company is also one of the most modern in the country. The chief highlight of the new setup is that it's linked up to a combined heat and power plant or CHP. Dr. Marc Kusche, managing director of Wernesgrüner Brauerei, tells us more. "Our decentral combined heat and power plant helps us to make enormous savings in energy. The total efficiency of the primary energy used here is over 85%, whereas the standard combination of a local heating system plus central power plant has a yield of about 45%." The CHP has a higher efficiency as the waste heat generated by electricity is used at source, enabling the CHP in Wernesgrün to supply a heat storage tank which is 22 meters high and five meters wide. This heat reservoir stores water of varying temperatures in different zones which is fed to the line (the bottle washer, crate washer, flash pasteurizer or CIP system, for example) as and when required. Heated water which is no longer needed on the line is also fed back into the storage tank. Surplus thermal energy from the system can be used to heat offices, warehouses and recreation rooms.
    On the returnable glass line with an output of up to 50,000 bottles per hour great value has been attached to minimized changeover times. When new products or bottles are scheduled for production, it only takes around 30 minutes to switch the equipment over. If crates are also to be swapped, conversion lasts about an hour. The line can be easily run by four operators who are now able to work in a very ergonomic, low-noise environment. Before the contract was awarded, the design of the brewery's new line was studied in 3D. Says Dr. Kusche, "This gave us the necessary safety of investment." What's interesting here is that Wernesgrüner Brauerei was one of the first breweries in the world to invest in the Innofill Glass DRS-ZMS series of fillers. "We're extremely pleased with the hygienic design and the very low oxygen filling process," smiles Dr. Kusche. "Compared to previous setups maintenance has also been greatly reduced. In addition we're also using less energy, water and detergent." The full contract not only included the Innofill Glass DRS-ZMS but also an Innoclean SEM bottle washer, an Innopack PPZ packer and unpacker and conveyors with automatic interior belt cleaning.
    (KHS GmbH)
    27.11.2013   KHS wins 2014 German Design Award for ClearLine    ( Company news )

    Company news The German Design Award, highly esteemed both within and outside Germany, is awarded once a year by the German Design Council, a body which has been helping mold the face of German design for 60 years. A total of 1,900 entries were submitted to the 2014 German Design Award committee and judged by 30 design experts from the fields of commerce, education and science.
    The German Design Award is normally presented to individual products which makes KHS' ClearLine system winning a prize all the more unusual. Michael Schlegel from Product Strategy at KHS GmbH says; "In ClearLine KHS has a uniform design concept which covers all the machines on a beverage filling and packaging system, visually underlining KHS' line expertise." Thomas Berger, project manager for ClearLine at KHS GmbH, adds, "Before we implemented the ClearLine project we carried out a full analysis of all of our machines. We went into the greatest detail to come up with a convincing result regarding function and design. Winning the 2014 German Design Award has confirmed that our great effort was worthwhile. In the future our existing machinery and all new KHS developments will be supplied in the ClearLine machine design."
    When developing the uniform ClearLine design for KHS machinery great importance was attached to producing a design which fully met various aesthetic, tactile and ergonomic specifications. The focus was also on simplifying functions and reducing the number of parts to improve clarity, cut down on the maintenance and cleaning effort, optimize the hygienic design and enhance transparency.
    KHS ClearLine was first presented with all its various aspects at drinktec 2013, the world's leading trade show for the beverage and liquid food industry. All of the new developments exhibited at the KHS booth had the stylistic traits of ClearLine machine design pertinent to machine operation, haptics and visuals.
    One feature of the ClearLine design concept is a new machine operating system known as the Human Machine Interface or HMI. In cooperation with the Fraunhofer IAO Institute an operating unit has been conceived which meets the needs and requirements of people with various backgrounds and qualifications. Role-based control and monitoring of machines and production lines is now combined on a uniform interface with identical hardware and software. The result is user-friendly machine operator prompting that employs simple buttons, colored graphics, easy-to-remember icons and interactive handling instructions. The concept can also be readily understood and processes easily grasped by new operators. The ClearLine operating concept has already won a number of awards, these being the red dot: best of the best, the iF product design award and the iF gold award.
    Thomas Detemple, managing director of ergon3Design and KHS partner in the development of ClearLine, says, "We paid very special attention to making the features of a machine or a line easy to understand, thus again boosting user friendliness and at the same time producing a design that meets KHS' high-tech standards and creates an atmosphere people are happy to work in."
    As regards the tactile aspects of the machinery, ClearLine uses identical handles on all KHS machines. So that the outward appearance of the design is consistent certain components are always included, such as identical lighting and specific colors, with a simple, subdued color scheme deliberately chosen. The main element here is a gray stripe which always encircles the machine at the same height. Prof. Dr.-Ing. Matthias Niemeyer, Chief Executive Officer/Chief Technical Officer of KHS GmbH, explains. "The combination of stainless steel and white, dark gray and silver for the lettering creates a sense of value, underlines the innovative design of the machine, has a clear design vocabulary and makes for transparency. The focus is on the product; this combination stands for premium quality and the design also integrates functional aspects. The neutral gray also provides the perfect background for colorful customer logos. By implementing our ClearLine design philosophy, as one of the world's leading manufacturers of filling and packaging technology for the beverage industry we're once again illuminating KHS' vision of being first choice in technology and service."
    (KHS GmbH)
    25.11.2013   Premium packaging technology for premium spirits    ( Company news )

    Company news Picture: Innopack-Kisters-WP-A-H

    Jim Beam bourbon whiskey is famous all over the world. Its story of success began in 1795 when Jacob Beam sold his first barrel of American whiskey. The Jim Beam range today includes the classic Jim Beam White Original brand and several other variants, such as Jim Beam Rye, Jim Beam Black, Jim Beam Devil’s Cut and Red Stag by Jim Beam in the flavors Black Cherry, Honey Tea and Spiced. This range of brands accounts for about 50% of all bourbon produced in Kentucky. If we consider that 98% of all bourbon distilleries in the USA are located in Kentucky, that's a very impressive figure.
    Jim Beam is now made by the company in its seventh generation. The brand is the flagship product of Beam Inc., the largest spirits company in the USA and the fourth biggest maker of spirits worldwide. The largest production site is the Old Grand Dad plant in Frankfort, Kentucky . This is where 12 million of the 38 million cases of Beam products bottled worldwide are filled and packaged (one case of spirits contains nine liters on average). Since 2010 the plant has consistently invested in KHS technology each time a replacement wrap-around packer was needed. There are now four KHS systems in operation: two Innopack Kisters WP A-H machines for the high-capacity lines and two Innopack Kisters WP 030 for lines with a lower output. Says Byron DuBois, "All four of our packers have proved convincing from day one. We're very pleased with them. As far as the Advanced series goes, we're profiting from countless highlights which we appreciate for our high-capacity range but don't necessarily need for our lines with a lower output." John Ballard, maintenance manager at the Frankfort plant, adds, "These highlights include operator-prompted format changeovers, for example, the use of identical servomotors with integrated servocontrollers and the great degree of flexibility this system gives us. As for the quality of the packaging, these KHS systems are definitely a cut above the rest." Back to DuBois. "It's this given premium quality which we need as a supplier of premium products." The positive experience the Old Grand Dad plant has had with its KHS wrap-around packs has been conveyed to other members of the Beam Group. As DuBois says, "It's always well worth sharing our experiences with others as this benefits the product quality and line efficiency at Beam plants all over the world."
    (KHS GmbH)
    20.11.2013   First-time investment in KHS stretch blow molding technology    ( Company news )

    Company news Picture: Rick Neal, head of the CCNNE production site in Londonderry, and Russ Brunner, plant engineer at CCNNE, are pleased. With our InnoPET Blomax Series IV we'll have a return on investment in just three years."

    For many decades the Coca-Cola Bottling Company of Northern New England (CCNNE) exclusively sourced its PET bottles from the converter Southeastern Container. Just recently, however, the company invested in a KHS InnoPET Blomax Series IV stretch blow molder and now produces 60% of its PET bottle requirements itself – with preforms supplied by Southeastern Container. John Palermo, the former vice-president of Operations at CCNNE and now chairman of the supervisory board at Southeastern Container, played a big role in this decision, saying, "The new generation of KHS stretch blow molders has the ability to change the prevalent attitude on the US market which is that beverage companies do best to procure their PET bottles from a converter. The reasons for this are that the Series IV is very easy to operate and very economical as far as the consumption of energy, compressed air and materials is concerned. It also manufactures at a much lower cost than has been the case to date." Rick Neal, head of the CCNNE production site in Londonderry, adds, "We'll have a return on investment here in just three years. This is an excellent result. I believe it's also very important that we're being extremely environmentally friendly in that we're saving on truck deliveries. As we now procure preforms instead of PET bottles from Southeastern Container, we're saving on around 1,800 truck journeys a year."
    The InnoPET Blomax Series IV at CCNNE has 28 blow stations and can output up to 63,000 PET bottles per hour. It's linked up to two PET lines which it supplies as required. At present the stretch blow molder manufactures 12, 16 and 20-ounce and 0.5-liter bottle variants (one ounce is about 0.03 liters). Neal states, "It's good to know that our new machine is extremely flexible and that in the future it can produce new bottles holding between 0.2 and 2 liters without any problems. What we also already find very advantageous are the very fast changeovers for the four sizes of bottle we currently produce." Says Palermo, "What is and will remain extremely important is the fact that the InnoPET Blomax Series IV gives us outstanding bottle quality. This is extremely significant for a bottle manufacturer and filler who's as quality conscious as CCNNE. It's not without reason that the company's won the Coca-Cola President's Award eight times. This is an annual prize presented to the most quality-conscious Coca-Cola bottler in the USA."
    (KHS GmbH)
    19.11.2013   The Innofill Glass Micro – perfect for small and medium-sized breweries    ( Company news )

    Company news Lakefront Brewery is situated in the former American brewing capital of Milwaukee, a fact owner Russ Klisch is very proud of. He's more or less grown up with the brewery trade; when he was a boy his grandfather often brought beer home with him after work. Says Klisch, "I thought it was a cool job if you got to bring beer home at night." With his background it's no wonder that Klisch wants to do his bit towards again making Milwaukee a center of the brewing industry. And with his successful Lakefront Brewery, he has! In order to meet the ever growing demand for quality Lakefront beers Klisch recently invested in an Innofill Glass Micro monoblocked with a rinsing and crowning system. "This was exactly the right decision to make," smiles Klisch. "The commissioning phase was extremely short and since then the filler has run like clockwork. Our lab results confirm that we have extremely low oxygen pickup in our beer which is a major aspect for a company that attaches such great value to quality." Klisch also praises the low CO2 consumption, the minimal amount of water used for cleaning thanks to targeted hygienic design and the very efficient use of energy through the application of servo motors.
    Lakefront Brewery has not only acted as a pioneer in investing in the innovative KHS filling system. For instance, in 2006 it created the first gluten-free beer to be approved by the US government. New Grist, as the tipple's called, is now the brewery's top product with sales notching up around 13,000 barrels a year. Lakefront was also the first brewery in the USA to brew a fruit beer since Prohibition and the second in the country to be bold enough to launch a pumpkin beer. What's more, in 1996 Lakefront introduced the first certified organic American beer to market in the form of Organic ESB or Extra Special Bitter.
    In 2012 the brewing company sold over 20 styles of beer in 33,000 barrels, including classic beers, seasonal beers and specialties brewed only once. Eighty percent of the products sold by Lakefront are attributable to its four classic brews New Grist, Riverwest Stein (an amber lager), Lakefront's Indian Pale Ale and Fixed Gear (an ale). With a share of 60% Wisconsin is still the biggest sales market for Lakefront Brewery which is also active in 35 other US states and exports to Canada, Australia, Japan and South Korea. Regional revenues and exports focus on one product alone: New Grist. According to Klisch, New Grist is growing on consumers not just for its health aspect but also thanks to its excellent taste which he describes as being "of fruity berries and a little reminiscent of cider".
    (KHS GmbH)
    20.09.2013   Even More Sustainability, Lower Operating Costs, and Greater Space Savings    ( Company news )

    Company news Picture: Ultra-Clean-Konzept-mit-Mini-Hygiene-Einhausung
    Criteria of the new KHS ultra-clean concept with integrated mini hygiene housing such as increased sustainability, flexibility, cost reduction, and space savings coupled with maximum microbiological safety are compelling.

    With its newly designed ultra-clean concept, KHS fully meets the demands of the beverage industry. Compelling are criteria such as increased sustainability, flexibility, cost reduction, and space savings coupled with maximum microbiological safety.

    Monoblocking the InnoPET Blomax Series IV stretch blow molder and the filler/capper system is prerequisite for this new system. The filler/capper system is integrated into what is known as a mini hygiene housing. What is special here is that unlike conventional glass hygiene housings, the floor area of the mini hygiene housing is enclosed which provides perfect protection from all outside influences. As its name suggests, the mini hygiene housing takes up very little space; about 40% less than the space required for classic hygiene isolators implemented in the past which also reduces detergent and sterile air consumption by approx. 20%.

    The measures taken to meet the requirements for ultra-clean filling of sensitive beverages such as fruit spritzers, slightly sparkling health and sports beverages, fruit juices containing preservatives, and non-alcoholic beer already begin at the stretch blow molder. Here, the heater area is equipped with a sterile chamber module where preforms are sterilized separately by a newly developed preform sterilization system. A sterile air airlock reliably separates the sterile chamber at the preform infeed as well as the discharge from the remaining heater area. The preforms are held in place during the entire heating and sterilization process by an active mandrel that has side openings through which a mixture of hot air and hydrogen peroxide flows directly into the preform body. All interior surfaces of the preform are sterilized equally reliably as the preform mouth. Final treatment in the sterile chamber module involves blowing sterile air around the entire body of the preform.

    The preform is transferred from the active mandrel to the gripper system and finally to the blowing station after application of the preset heating profile within an enclosed area in which a continuous downward flow of sterile air prevails. The same principle is used when the freshly blown PET bottles are removed from the stretch blow molder and transferred to the transfer segment leading to the filler/capper system. The PET bottles first pass through a sterile airlock located inside the transfer area that keeps the dry area of the blow molder strictly separated from the wet filler area. The bottles pass through a cooling module in the next step. A new feature in this area: water with chlorine dioxide added is used that not only cools but also sterilizes the bottle bases. Perfect bottle sterilization is thus achieved in conjunction with the preceding preform treatment that focuses chiefly on sterilizing bottle interiors, bottle mouth areas, and bottle side walls.

    Located above the enclosed transfer segment is a HEPA (high efficiency particulate air) filter that provides a constant supply of sterile air. Similar to the transfer area, a sterile air atmosphere is continuously maintained in the area of the mini hygiene housing that flows out of the system parallel to the bottle flow in the filler and capper area up to the bottle discharge where it is either finally discharged to the production shop or specifically extracted. In the mini hygiene housing, the air is additionally discharged through openings in the upper and lower areas of the devices created by the overlap of the rotating machine carousel and the stationary components.

    Only the bottles, the bottle grippers, and the filling spouts are integrated into the mini hygiene housing in the area of the filling system while the filling valves, product bowl, electronics, and control systems are located outside the hygiene area together with the servo drives of the capping elements. Cleaning nozzles are installed in such a way that they perfectly reach the transfer stars, filling valves, and capper elements, as well as all interior surfaces. Exceptionally reliable automatic sanitizing is a given. The cleaning circuits are fed by a newly developed KHS hygiene center that, among other things, incorporates the chlorine dioxide preparation unit.

    The filling system used to optionally fill carbonated or non-carbonated beverages is an Innofill DRV-UCF that operates according to the principle of volumetric, electromagnetic inductive flow metering. A special feature here is the twin control of certain functions in the filling valves, which eliminates a considerable number of gas valves with pneumatic and electrical control and thus reduces the cost of maintenance and repairs. Each of the filling valves can nevertheless be switched individually. A filler equipped with 140 filling stations, for example, now only requires 280 gas control valves instead of 420. When filling products in an inert gas atmosphere (e.g. using CO2), the proportion of inert gas in the pressurized bottle can be freely adjusted depending on the oxygen sensitivity of the beverage being filled. Adapting the filling atmosphere to the requirements of the particular type of beverage reduces CO2 consumption costs. The Innofill DRV is the only filling system that does not require separately controlled lifting elements to press bottle mouths against the filling valves. Bottle mouths are sealed against the filling valves by transferring the pressure inside the bottle to the neck ring holder via an aseptically designed expansion joint located inside the filling valve. For a filler equipped with 140 filling stations, for example, this eliminates yet another 140 pneumatic cylinders including the related pneumatic and electric control elements. At the same time, the contact forces are very exact. If the filling pressure is high, the bottles are pressed against the valves with the accordingly greater amount of force while lower contact pressure is required at low filling pressures. This method not only handles plastic bottles particularly gently, it also reduces the number of wear parts, lengthens the periods between maintenance intervals, and increases the efficiency of the filling system.

    A drop of liquid nitrogen can be placed in the head space of each bottle when filling non-carbonated beverages to achieve exceptionally high bottle stability. The Innofill SV-ACF screw capper is the capping system of choice.

    The InnoPET BloFill ultra-clean monoblock, equipped with an integrated mini hygiene housing capable of processing up to 60,000 plastic bottles per hour ranging in size from 0.1 to 3 liters, is controlled by the multiple-award winning KHS HMI operator panel (Red Dot Award and iF award).
    (KHS GmbH)
    29.08.2013   KHS Steps Up Involvement in Africa    ( Company news )

    Company news KHS continues to consolidate its position in the African market by acquiring Sen-Tech and founding KHS East Africa Ltd. just recently. KHS has enjoyed a 30-year partnership with Sen-Tech and the Afrotech Consultant (ATC) sales organization, which were KHS representatives for the East African market. KHS East Africa Ltd. will now be directly handling all sales, service, and after-sale activities in the region.
    The aim of Nairobi-based KHS East Africa Ltd. is to intensify customer proximity through direct local presence. Prof. Dr. Ing. Johann Grabenweger, CSO, KHS GmbH says, "We see an enormous potential in the East African market now and in the future as well. The founding of KHS East Africa Ltd. documents the great importance we attach to East Africa specifically and Africa in general."
    Denise Schneider-Walimohamed is the Managing Director of KHS East Africa Ltd. Through her many years of service at Sen-Tech she is equally as well known in the trade as the other 45 former Sen-Tech employees who now work for the KHS East Africa. Schneider Walimohamed says, "I welcome in all respects the step taken by KHS to invest in East Africa. For customers in the beverage, food, and non-food industries, this means among other things the security that KHS, as one of the major global players in filling and packaging technology, will continue to provide best possible service in the future. At the same time the people formerly employed by Sen-Tech are very pleased with KHS' commitment to them and their country." The employees of KHS East Africa Ltd. will be moving into new offices in September. Opening ceremonies are scheduled to be held in October to which customers from all over East Africa are invited.
    Markus Auinger, Executive Vice President Market Zone Africa/Near and Middle East, KHS GmbH explains, "We will now be quickly starting to expand our sales and service activities in the fifteen countries of East Africa." Markus Knabe, head of KHS GmbH's Service Div. worldwide adds, "The region will profit from our comprehensive service expertise. KHS Field Service is synonymous with around-the-clock support. Be it a matter of resolving a line standstill, carrying out upcoming maintenance, installing required upgrades, or taking inventory of spare parts on site - we as the point of contact are ready to handle all these issues."
    By establishing KHS East Africa Ltd., KHS now has a total of four service branches in the African market. Other service facilities are located in Johannesburg, South Africa; Lagos, Nigeria; and Cairo, Egypt. The company has been active in the African market for over 40 years and was the first international supplier of filling and packaging systems for the beverage, food, and non-food industries to establish its own service facilities here 30 years ago.
    In 2012, Africa's share of KHS' total sales was in excess of 10%. Also because of the growing economic power of Africa, Auinger expects further annual growth rates of 5 to 7% for KHS in Africa in the coming years. He anticipates a particularly high increase in East Africa. Auinger has been the head of the Africa/Middle East Market Zone since early March 2013 following in the footsteps of Erhard Magin who managed this regional office successfully for more than 20 years. After completing his studies in brewing and beverage technology at the Technical University of Munich Weihenstephan, Auinger began his professional career in the fields of engineering and project management and has been active in the beverage industry worldwide as an engineering manager and sales manager for almost 20 years. He joined KHS two years ago as the head of Regional Center Middle East. In his new position, Auinger intends to further expand the markets entrusted to him to generate increased competitiveness in keeping with the Fit4Future initiative pursued by KHS. Auinger says, "Our goals in these markets are identical to those of KHS worldwide. We are striving for technology and service leadership in this region as well." Auinger is supported in his endeavors in Africa by Jörg Thomas, who has held the position as the head of Regional Center Africa since the beginning of July 2013. Mr. Thomas is a college-trained brewer and has gained many years of experience particularly in the fields of brewing and process engineering from his work at leading companies in the brewing industry. He has an extensive knowledge of Africa and has very good connections in the region.
    (KHS GmbH)
    16.08.2013   KHS PET event a great success    ( Company news )

    Company news "A successful event where extensive expertise was communicated in concentrated form while focusing on groundbreaking innovations which provide real added value" was the unanimous verdict of those who took part in the KHS PET event. In June more than 100 international KHS customers visited the pioneering event which started with a series of talks and finished with a tour of the new production shop at the KHS Corpoplast plant in Hamburg, Germany.
    Prof. Dr.-Ing. Matthias Niemeyer, CEO/CTO of KHS GmbH, said, "As a technological leader whose vision is to be first choice in technology and service we believe it’s very important to keep up a continuous dialog with our customers, enabling us to always gear our new developments to the requirements of the industry. KHS events are an excellent opportunity for this, creating a win-win situation for both us and our customers. At events like these we provide information on how specific competitive advantages can be achieved by applying new technologies and learn from our guests what the additional requirements for the future are."
    This is a procedure which Toshihiro Ueki, general manager of Shonan Plant Kirin Beverage Company Limited, and Thomas Reise, technical director of Hansa-Heemann AG, emphasized when talking about their experience with KHS. They reported on many years of successful cooperation with KHS, on outstanding service, and on the continuous exchange of information with their trusted supplier. At the same time they were highly impressed with the latest generation of stretch blow molding machines, the InnoPET Blomax Series IV. Compared with the previous generation the new model saves up to 30% in blowing air, up to 43% in electrical power and up to 49% in cooling power, results which have been confirmed by the TÜV SÜD Energy-efficient System Technology certificate.
    The latest innovations to be highlighted during the PET event were a new ultraclean concept with an integral mini hygiene housing, the direct digital printing of PET bottles, and the newly developed FreshSafe PET marketing concept which documents the advantages of further improved Plasmax coating technology from the consumer’s point of view. The event also focused on the KHS Service department with its wide range of services from the fast supply of spare parts to individually tailored maintenance contracts.
    The newly developed ultraclean technology monoblocks the InnoPET Blomax Series IV stretch blow molder with the filler/capper section which is incorporated into what’s known as a mini hygiene housing. The advantages of this concept are the system's small footprint, improved sustainability and reduced costs while providing maximum microbiological safety.
    Instead of conventional roll-fed labeling, the innovative Innoprint generation of labeling machines makes it possible to print digital images directly onto PET bottles. Here, plastic bottles are printed with food-grade UV inks which ensure a brilliant color image. One particular advantage of direct printing is the rapid response this enables. Take a sporting event, for example; among other things, direct printing allows bottlers to offer the consumer a filled PET bottle bearing a picture of the winning team shortly after the end of an event. The required print image can be transmitted directly from the computer to the control unit of the labeling machine. This enables international beverage companies to send print files to all of their plants which can then immediately start printing at the same time – wherever they are in the world.
    How can the advantages of PET bottles with an internal Plasmax coating (an ultrathin film of SiOx or pure glass) be communicated to the end user? KHS Plasmax went into this question in great detail, commissioning a consumer study on the subject. The result was that consumers showed great interest in drinking out of a PET bottle which protects the product with an internal coating made of pure glass. Seventy-six percent of those surveyed would choose this option, they said, and believe it’s a good idea to decorate bottles like these with a FreshSafe logo which stands for quality protection, a long shelf life, a fresh taste and 100% recyclability. It’s interesting to note that nearly all of those who took part in the study and were impressed by the new Plasmax technology were prepared to pay more than usual for a beverage in the FreshSafe PET bottle.
    Following the highly interesting presentations the next item on the agenda was a tour of the KHS Hamburg plant. Of particular interest here was the new production shop with an additional assembly area of 2,300 m² which was erected at the end of 2012. The plant therefore now has about 11,000 m² of assembly space, around 3,500 m² for logistics use and an office area of approximately 6,500 m². As a result of the global success of the InnoPET Blomax Series IV generation of stretch blow molders KHS plans to increase the assembly space by a further 2,300 m² for 2015.
    Thomas Karell, managing director of KHS Corpoplast GmbH, says, "There are now over 1,500 KHS Corpoplast stretch blow molders in use around the world, including approximately 220 InnoPET Blomax Series IV stretch blow molding machines. This is proof that our new generation of plant technology is being very well received. Everything’s set for further growth."
    (KHS GmbH)
    16.07.2013   Decades of excellent partnership    ( Company news )

    A lot has changed for what's now Samson Brewery since the beginning of 2012. The reason? It was in this year that American brewery giant Anheuser Busch bought into the company and procured the rights to the name "Budweiser Bier". Since then, what used to be Budweiser Bürgerbräu (the Budweis civic brewhouse) has acted under the name of Samson Brewery, selling beer brands Samson, 1795, Pito, and Dianello in place of Budweiser Bier.

    Lubos Martis, master brewer at Samson, says, "Consumers first have to familiarize themselves with these brands. We thus had a drop in sales in 2012 which we aim to recover by 2014." It's easier for the over 50s to get used to the brand beers than the younger generation, as from 1960 to 1991 the brewery already operated under the designation of Samson Brewery as part of the South Bohemian Brewery Group, producing the aforementioned beer brands. Says Martis, "Thanks to this our allegedly 'new' brands create a sense of retro for this target group." In order to encourage consumption among young adults, shortly after the merge the company launched a shandy under the Samson logo to market. This proved to be a successful move, with Samson, now in four types of shandy, selling 9,000 hectoliters within a year and winning the prize for the best shandy in the Czech Republic from the Czech Brewers' Association.

    Even if the brewery's recent history may have been somewhat turbulent, as far as investments go the brewery has been consistent in the last couple of decades. In 1994 it invested in KHS kegging technology with an output of 110 kegs per hour. In 1996 this keg line was expanded to work at twice the capacity and in 1999 the brewery's existing filter system was replaced by the Innopro Getra Eco. In 2012 the filling system was up for renewal, with the company clearly opting for the Innofill DPG-ZMS. Martis elaborates. "The main reason for again investing in KHS equipment was that we are extremely satisfied with the technology and after-sales service. The outstanding results the Innofill DPG-ZMS achieves regarding oxygen values and CO2 consumption are another. Many breweries already using this setup confirmed this on asking before we invested. Incidentally, in practical operation the quality of the filling is exactly as predicted prior to utilization."

    At present Samson Brewery produces 150,000 hectoliters per year and is one of the 20 largest breweries in the Czech Republic. In the export business it's number 10 among Czech breweries. By presenting itself as a traditional brewery with a high potential for innovation and an advertising strategy to match, in the future the brewery hopes to be able to persuade young adults in particular to increasingly enjoy their quality beer brands.
    (KHS GmbH)
    05.07.2013   Austrian Brauerei Zipf upgrades bottle washer from 1991 with full conversion package    ( Company news )

    Company news Boosting sustainability and cutting costs were the two main reasons for Brauerei Zipf from Upper Austria investing in a conversion for their outmoded KHS washer for non-returnable bottles. The brewery first asked itself if it should invest in new machinery or upgrade the existing setup. Master brewer Dr Günther Seeleitner describes the decision-making process as follows: "Our KHS bottle washer from 1991 has worked perfectly up to now and we're extremely pleased with it. Why should we replace it when we can profit from the benefits of a new machine by simply upgrading it?"
    Zipf therefore ordered a full conversion package which included the replacement of the steel carriers with energy-saving bottle carriers equipped with plastic bottle pockets and the integration of a fresh water control and pump drive system into the cleaning concept. The existing control unit was also removed to make way for a new controller.
    The results following the upgrade are impressive. The fresh water consumption has sunk from 340 ml to just 200 ml per bottle; instead of 1.5 liters of caustic per 1,000 bottles to be washed, only 0.8 liters of caustic are needed, with the caustic carryover reduced by 14.3 ml per bottle. The same ratio of additives is also saved. To boot, the amount of energy used has dropped from 15 to 12 kilowatts per hour. According to Zipf's calculations, on the basis of the modernizations to their bottle washer alone the brewery will cut their water consumption by 14,000 m³ per year, their electricity consumption by 49,500 kWh, the amount of steam used by 560 metric tones, the use of NaOH by 97 tons, and the consumption of other chemicals by 17 tons.
    Within the Union Zipf is known as the innovative brewery, famous for its Zipfer brand and range of Edelweiss wheat beers. Both brands are widely known in Austria and also exported, with annual sales notching up about one million hectoliters. In 2012 the entire Brau Union Österreich sold 4.55 million hectoliters, meaning that the brewery group accounts for over half of the beer consumed in Austria (8.54 million hectoliters) and thus has a great impact on the Austrian beer market. A study recently commissioned by the Union revealed that beer is a subject that is close to the Austrian heart, with 92% of those asked considering beer to be a composite part of Austria's culture. This is small wonder considering the high per capita consumption of beer here; at present, the Austrians hold second place to the Czech Republic in the international consumption stakes at 107.7 liters drunk per head per year.
    (KHS GmbH)
    13.05.2013   Keg technology from the market leader     ( Company news )

    Company news Picture: Kaon Brewery has an excellent partnership with KHS. Kastriot Stroka, the brewery's engineering manager (right): "This is what we expected; we didn't opt for keg technology from the market leader without good reason." Also pictured: Nenad Delovski, manager of the KHS Branch Office in Belgrade.

    There are five breweries in Albania at the time of writing. One of these is Kaon Brewery. The company, owned by brothers Alket, Artan, and Kastriot Stroka, started out as a small craft brewery in 1995, of which there were several hundred at the time. Kastriot Stroka, engineering manager at Kaon, tells us more. "Our success is primarily due to the fact that we just love making beer and believed early on that the quality of our beer is extremely important. Our motto is still to put quality at the very top of our list of priorities." It thus comes as no surprise to learn that the brewery recently invested in KHS keg technology in the form of an Innokeg Till CombiKeg. Says Kastriot Stroka, "We consciously invested in plant engineering from the world's market leader for keg technology. Our new keg washing and racking machine perfectly meets our high demands for quality. At the same time we're profiting from its compact design, flexibility, sustainability, and ease of operation."
    Kaon's Innokeg Till CombiKeg R5 racks the brewery's two brands of Kaon Lager and Kaon Red Ale into 30 and 50-liter kegs. What the Strokas find particularly advantageous about their new acquisition is that with it they are prepared for all future eventualities. Should the hospitality trade want different types of keg at a later date, the kegging system is perfectly able to cope with a wider assortment of beverages, such as those that don't contain alcohol.
    At present Kaon Brewery sells 40% of its beer in kegs. Thanks to their new investment ,sales in kegs may well increase in the future if sales continue to rise. Considering the string of successes so far, the prospects for future growth look good. In 2000 the brewery output just 1,000 hectoliters, for example. By 2005 this figure had risen to 5,000 hectoliters, and to 20,000 hectoliters by 2008. In 2012 the brothers sold the incredible 70,000 hectoliters mentioned above. Kaon Brewery is partly benefiting from a growing consumption of beer in Albania which is increasing annually per head parallel to the average income. The current statistic is 30 liters. Kaon Brewery has also profited from the population getting back to drinking national beers. At the end of the 1990s, for instance, 90% of all beer imbibed in the country was imported; this percentage has since dropped to 40%, the reason being that beers from Albania are increasingly convincing consumers. Back to Kastriot Stroka. "With the aim of becoming the leader in quality, we react according to consumer demands in all respects. This is the only way we can continue to stay competitive. Our new Innokeg Till CombiKeg will greatly help us to implement our uncompromising strategy of providing only quality."
    (KHS GmbH)
    07.05.2013   Innovative generation of Innofill Glass Micro fillers now also for the wine & sparkling wine sector    ( Company news )

    Company news In the Innofill Glass Micro KHS recently launched a new series of fillers to market that have been specially designed for small and medium-sized beverage companies. The brewing and soft drinks sectors were the first to profit from the system which can be used as a platform for various computer-controlled KHS filling machinery. The Innofill Glass Micro is now available to the wine and sparkling wine trade. Here, too, the need for hygienic, top-quality filling systems for the low to medium capacity range is constantly growing worldwide.
    Customers who procure an Innofill Glass Micro machine will profit from KHS' vast experience in top-performance filling technology. Many of the established components found in high capacity machines and subject to permanent further development are utilized here, among them filling systems, drive and control systems, capping and corking elements, rinsing stations, and lifting elements. Plant operators will also benefit from the use of a number of highly developed KHS technologies which can give them the added extras of very low oxygen filling with low consumption of CO2 and extremely high filling accuracies, for example.
    The Innofill Glass Micro for the wine and sparkling wine sector can be fitted with 24 to 60 filling stations and fill between 3,000 and 20,000 bottles per hour, these holding from 0.1 to 2 liters. Both glass and PET bottles (optional) can be processed. The machine is available in three different sizes.
    The DPG Trinox filling system has been implemented here, permitting both balanced pressure and pressurized filling. Operators can switch between the two by simply pressing a button. Prior to filling, on the DPG Trinox single or multiple pre-evacuation is possible with an interim purge of CO2 or nitrogen. If pressure filling is selected, there is a pressurization process before filling begins. In the DPG Trinox the product is deflected down the inside walls of the bottle via a swirler gas lock; the plastic spreader rings previously used as a deflecting system and which protruded into the bottle neck are no longer needed, ensuring maximum hygiene and product safety. The filling phase is completed when the product rising in the bottle closes the return gas tube. Another important aspect is that product, gas, and CIP media are fed in through hygienic seals, membranes, and expansion joints that prevent the formation of any deposits or biofilm.
    Utilizing the proven Trinox process in the DPG Trinox filler also enables precision fill levels to be achieved. The process is as follows: from the Trinox channel a pressure is built up on the level of the product in the previously overfilled bottle which is 0.3 to 0.5 bars higher than the set filling pressure, both in the case of balanced pressure and pressurized filling. This positive pressure ensures that excess liquid is forced gently back into the ring bowl through the Trinox tube positioned in the center of the bottle and filling valve. The process ends exactly at the moment that a minimum defined gap is produced between the level of the product and the end of the Trinox tube. The extremely precise fill levels produced by Trinox technology help to save money for product and also allow natural corks to be processed.
    Another huge plus of the Innofill Glass Micro is KHS' twin-valve control system. To date the DPG Trinox filling setup required three pneumatic switching functions per filling station, these being one gas cylinder apiece for evacuation, snifting, and the Trinox function. As a result, three solenoid valves, three pneumatic hoses, three electronic outputs, and three sets of wiring were also required per filling valve. The filler with 60 filling stations thus had 180 gas valves, 180 solenoid valves, and 180 electronic outputs with hoses. In the twin-valve control system two filling valves have been combined to make one processing unit, therefore cutting down on gas valves and solenoid valves and halving the number of electropneumatic control units. In turn, this reduces the complexity and maintenance of the machine, the number of spare parts needed, and costs for operation.
    Up to three different closure systems can be monoblocked as required with the Innofill Glass Micro DPG Trinox, with natural corks, aluminum screw caps, or PE stoppers all doable. This innovative filler can also be monoblocked with an upstream rinser if necessary.
    All told, the Innofill Glass Micro for the wine and sparkling wine industry is a filler for the low to medium capacity range that provides outstanding filling quality and also helps to save both product and costs. In addition, it is also extremely flexible, easy to changeover, and consistent in its hygienic design.
    (KHS GmbH)
    01.03.2013   Focus on Resource Efficiency    ( Company news )

    Today, the beverage and food industries are faced with great challenges where further globalization is combined with growing competitive pressure. It thus follows that in order to survive in a competitive environment high quality and cost-efficient production is equally as necessary as foresighted actions in areas such as sustainability.
    As an internationally active manufacturer of filling and packaging equipment, KHS always supplies the beverage, food, and nonfood industries with top quality technical systems that not only meet the demand for cost-efficient production but also take the aspect of sustainability into consideration. This was recently documented, for example, by the "Energy-efficient System Technology" certificate awarded by TÜV SÜD for two new developments at once: one for the first design of the Innofill Glass DRS-ZMS filler series and the other for the InnoPET Blomax Series IV generation of stretch blow molders. KHS' most recent initiative which is focused equally on cost reduction and sustainability: "Resource-efficient development and optimized operation of filling lines in the beverage and food industries by implementing innovative simulation software." KHS successfully applied for a joint research project together with the Department for Production Systems of the Ruhr-Universität Bochum. This research and development project is promoted with state and EU funds within the Ziel2-Calls "Ressource.NRW" and is supported by the State Agency for Nature, Environment and Consumer Protection in North-Rhine Westphalia.
    The project is to begin by carrying out studies in practice involving thorough analysis of the current situation of one refillable glass bottling and packing line each at the Veltins and Warsteiner breweries with the aim of deriving initial heuristics and algorithms. This is to be followed by identification of smart operating points in the lines coupled with the related optimization of the resources used during various operational states. The next step planned is to generate resource-conserving control circuits. The final step is to determine ideal system layouts for new lines in terms of conservation of resources and preparing automation requirement specifications for efficient operation.
    Mario Beck, head of sustainability/TCO Central Technology Management Division at KHS says, "In addition to the newly learned lessons, the simulation should also reflect KHS' years of process knowledge. This expertise goes beyond the existing engineering used in refillable glass bottle lines to bottle and pack beer and extends to filling lines for PET, cans, and kegs. This will achieve rebas' goal of developing simulation software that can be implemented for a widest variety of systems."
    Consistent implementation of the rebas findings will further increase the sustainability of KHS line concepts. In concrete terms, this means a constant decrease in the consumption of energy and raw, operating, and process materials at the same level of output volume. This increase in efficiency forms an important basis for the further development of the KHS product portfolio and improving the competitiveness of KHS' customers.
    (KHS GmbH)
    21.02.2013   KHS InnoPET Blomax Series IV awarded the     ( Company news )

    Company news ... TÜV SÜD

    Picture: KHS has been awarded the coveted "Energy-efficient System Technology" certificate from TÜV SÜD for the second time - this time for its InnoPET Blomax Series IV generation of stretch blow molders. Dr. Michael Bunk (on the right in the picture), head auditor at TÜV SÜD, presenting the certificate to Dr. Thomas van Hamme, head of Design Engineering and Development at KHS Corpoplast.

    The beverage, food, and non-food industries demand high quality technical systems that include not only sustainability aspects but specifically reduce the cost of running production operation as well. KHS traditionally meets this demand by supplying innovative filling and packing technology. In the development of the InnoPET Blomax Series IV generation of stretch blow molding machines, emphasis has also been placed on reducing overall operating costs and conserving resources in the production of premium PET bottles. This machine has met fully the high expectations of KHS and its customers around the globe since it was first launched to the market and has now received an award. As an independent testing and certification company, TÜV SÜD awarded the InnoPET Blomax Series IV the "Energy-efficient System Technology" certificate - a highly recognized award worldwide.
    The presentation of the coveted TÜV certificate was preceded by a comparison of the InnoPET Blomax Series IV and the predecessor model, the InnoPET Blomax Series III, in practical operation. Identical container types were produced on both machines. The result: the InnoPET Blomax Series IV reduces the comparative blow air consumption by up to 30%, it requires 43% less electrical power, and requires 49% less cooling capacity. To date, KHS Corpoplast predicted a 15% decrease in the compressed air consumption and a 25% reduction in the energy consumption and cooling capacity. The figures determined by TÜV SÜD were thus considerably more positive than those KHS Corpoplast previously communicated to the industry.
    The newly developed heater above all contributes towards the high energy savings. InnoPET Blomax Series IV uses short-wave near infrared radiation instead of classic infrared radiation to heat up the preforms. This cuts the time required for heating preforms in half versus the InnoPET Blomax Series III. As a direct result, the space required for the heater of the InnoPET Blomax Series IV is only half of the original space requirement. Specifically redesigning the valve block brought about a reduction in the compressed air consumption of the InnoPET Blomax Series IV. The dead space volume (volume of air applied at high pressure but which does not help to shape the PET bottles) is reduced by about 30%.
    Dr. Thomas van Hamme, head of Design Engineering and Development at KHS Corpoplast says, "Even when it comes to energy efficiency and TCO, KHS Corpoplast has always been a pioneer among suppliers of stretch blow molding equipment. With the "Energy-efficient System Technology" certificate from TÜV SÜD we are now setting yet another benchmark."
    Incidentally, in addition to further increasing the energy efficiency the InnoPET Blomax Series IV offers numerous other benefits in comparison to the previous generation. Using an active mandrel has optimized preform handling during the process, for example. Complex transfer systems are thus no longer necessary. The blowing stations have also been re-engineered. Because the blowing stations are staggered on the blowing wheel and are now only opened on one side, more blow stations than were previously possible can be integrated onto one blowing wheel of the same size. Each individual blowing station is now able to produce up to 2,250 bottles per hour (Series III: 1,800). The servo motor-driven stretching process within the blowing station additionally ensures that the speed of the blow molder is always perfectly adapted to the speed of the filling system and that materials are optimally distributed within the PET bottles. In terms of specific material savings, the InnoPET Blomax Series IV thus uses preforms comprised of PET materials that have been optimized down to the last tenth of a gram.
    Dr. Michael Bunk, head auditor at TÜV SÜD says, "We are very pleased that an internationally active company such as KHS places such great importance on sustainability in general, and energy efficiency in particular. This strengthens not only the company's competitiveness but also demonstrates at the same time a high degree of responsibility towards the environment and society."
    Incidentally, this is the second time that KHS has been awarded the "Energy-efficient System Technology" certificate from TÜV SÜD. The award was presented for the first time for the first model of the new Innofill Glass filler, the first platform-based product in the new filler series for glass bottles. With this machine KHS recently heralded a generation change in filling machines for glass bottles.
    (KHS GmbH)
    11.01.2013   Khmer Brewery in Cambodia again invests in a KHS turnkey canning line    ( Company news )

    Company news KHS technology part of the company philosophy

    Khmer Brewery in Cambodia again invests in KHS technology. Peter Leang, senior executive vice-president of Khmer Brewery, recently signed a contract for delivery of a turnkey canning line which can output 60,000 0.33-liter cans per hour. Leang states, "There are two definitive reasons for investing in a further KHS line. The first is that we're extremely satisfied with KHS machinery. The second is that KHS gives us excellent customer care and is always on hand when and if service is required."
    Khmer Brewery, opened at the end of 2011, currently operates three KHS turnkey systems: a canning line, a glass line, and a keg line. With its new investment the brewery will be able to fill and pack up to 90,000 0.33-liter cans per hour. Canned beer is popular in Cambodia mainly because beer in cans is easy to transport and the people here are familiar with this type of container from imported products. Typical for the country, therefore, the amount of beer sold in cans accounts for 85% of Khmer Brewery's total sales. With the realization of a planned boost in sales, the new investment had to materialize fast. In the first half of 2012 Khmer sold 300,000 hectoliters of beer, with this figure crossing the 750,000-hectoliter mark at the end of this year. In 2013 Leang is reckoning on selling around 1.3 million hectoliters of the beverage. His aim is to push sales figures up to four million hectoliters by 2017, thus becoming top of the list of Cambodian breweries. Leang states, "Our strategy of providing the people of Cambodia with only the best quality in the form of our Beer Cambodia brand is paying off. This is reflected in our high sales growth. In the future, too, we'll continue to act as the brewery from Cambodia for Cambodia."
    The heart of the recently ordered KHS turnkey canning line is an Innofill DVD filling system with over 76 filling stations. Cans are fed to the filler following fully automatic depalletizing by an Innopal AS1H and conveying through the vacuum bridge. The principle of electromagnetic inductive flow metering is used here to achieve maximum fill level accuracy. Deviations in can capacities supplied by various manufacturers are therefore no longer a matter of concern. The Innofill DVD features smooth product passages throughout the machine from the ring bowl to the filling valves. Aseptic membrane and sealing technology is used in all Innofill DVD filling valves and in all other channels and routes exposed to the product. Leang smiles. "What we like most about the Innofill DVD besides its ultra-precise filling is the extremely low-oxygen filling process. This enables us to perfectly preserve our outstanding beer quality." Leang considers another main aspect of quality to be KHS' PU control utilized in the Innopas PISC pasteurizer. With it over-pasteurization is reduced to a minimum and high flavor stability ensured even if multiple stops occur.
    As with its first investment Khmer Brewery has opted to pack cans into cartons on the new canning line. For this purpose there are two Innopack CA carton openers placed upstream of the Innopack PPZ packer. These set up folded cardboard box blanks, fold in the bottom flaps, and glue them with hot melt. An Innopack CV installed after the can cartoner ensures flawless glue application and perfect carton sealing. An Innopal PBN1 then palletizes the cartons with level compensation and automatic layer formation. Says Leang, "In KHS we've found the trusted partner we'd like to shape the future with. We feel we're in the best of hands on all counts."
    In Cambodia, drinking beer is in – not just because Cambodians like beer but because the consumption of beer also implies a certain status. Observers anticipate annual rises in beer sales on the Cambodian market of between 15 and 20%, based on a present per capita consumption of 18 liters of beer per annum.
    (KHS GmbH)
    07.01.2013   For the bottling of still water under ultraclean conditions    ( Company news )

    Company news Picture: The new mini hygiene housing has been developed for the ultraclean filling of water in PET bottles. Its advantages lie, among others, in the enclosed, hygienic design, the little amount of space required, and its low maintenance requirements and thus reduced costs.

    With the launch of a new mini hygiene housing for the ultraclean filling of water in PET bottles KHS is meeting a major demand voiced by the beverage sector. Whereas the glass hygiene housing usually found in ultraclean applications is open to the floor, the base of the mini hygiene housing is closed. This means that the filling area is completely sealed and thus protected from any outside influences. Another advantage of the new mini hygiene housing is that the system takes up very little space, thus cutting costs and generally saving over 30% of space compared to standard systems. The consistent implementation of hygienic design creates perfect conditions for fast and efficient cleaning where the amount of air and cleaning agents consumed is also lower than in conventional sanitary rooms.
    The mini hygiene housing is chiefly destined for equipment where the stretch blow molder is monoblocked with a filling machine. If required, it can also be used where bottles are fed in by an air conveyor. In the monoblock concept the bottles first pass through an airlock after being stretch blow molded. This airlock ensures that the wet area of the filler is kept completely separate from the dry area of the blow molder, thereby eliminating the risk of corrosion in the blow molder. When using the mini hygiene housing sterile air is permanently applied to the transfer stars leading to the filler section. Here, HEPA (high-efficiency particulate air) filters are integrated into the system to provide a constant supply of sterile air. In the filler and capper area the flow of sterile air, which is kept at a slight overpressure, is conducted parallel to the bottle flow up to the point where the bottles leave the system. Pressure control and pressure monitoring equipment can be included as options. The air in the system is removed through strategically positioned openings in the upper and lower area of the machine which are created by the overlap of the rotating machine carousel and the static components. After the capping process the sterile air can be optionally extracted and discharged. This is especially recommended if water containing ozone is scheduled for filling.
    The setup includes an Innofill NV filling system which processes various sizes of bottle holding from 0.1 to 3 liters at rates of between 15,000 to 72,000 bottles per hour. There are also systems for different types of bottle mouth available. The Innofill NV non-contact filling process with a free-flow filling valve gives customers microbiological and hygienic safety; the bottle mouths are neither pressed nor sealed against the filling valves and there is no contact between the valve components and the bottle mouths. As a result, there is no question of product wetting. The Innofill NV also uses volumetric impeller flow metering. This is a very simple, proven system of measurement based on the volumes of liquid transported in the impeller areas. These measurement devices have been specially developed to measure beverage volume flows, taking all aspects of hygiene into full account. Signals are transmitted without contact to an integrated sensor that derives the relevant fluid flow rate from the measurement signals. Impeller flow metering enables demineralized water to be filled that does not have a significant measurable level of conductivity. Electromagnetic inductive flow metering can also be implemented if desired. The closure system used here is an Innofill SV-ACF, a computer-controlled screw capper which fully adjusts to the individual specifications of the closures used. The distinct separation of capping movements into rotational and vertical motions and a sophisticated hygienic design that provides perfect cleaning conditions are in full keeping with the concept of hygienic filling.
    Cleaning nozzles have been installed in the mini hygiene housing that are specifically aimed at the transfer stars, filling valves, capper elements, and all interior surfaces for perfect results, ensuring automatic, absolutely reliable sanitizing. Specifically fitting the system with glass doors also gives customers absolute transparency and fast access to individual elements in the interior of the machine. This makes maintenance an easy task. Both the transfer stars and filler and capper have separate servo drives that are located in hygienically designed columns. This means that not only the housing is engineered according to hygienic design criteria but also the entire machine as well.
    The filler/capper monoblock encased in the mini hygiene housing and stretch blow molder are controlled by the multi-award-winning KHS operator panel (red dot award and iF award) with an integrated RFID system. The KHS panel excellently combines ergonomics, navigation, and design. The result is user-friendly machine operator prompting that makes use of buttons, colored graphics, easy-to-remember icons, and interactive handling instructions, all of which are self-explanatory.
    (KHS GmbH)
    12.12.2012   Gap now closed    ( Company news )

    Company news With the Innosept Asbofill ESL KHS is now launching a linear filling machine that has been specially developed for the bottling of extended shelf life or ESL beverages for the cold chain. In doing so KHS is finally closing the gap between classic and aseptic filling technology. In developing the new series KHS made specific use of its expertise in the field of aseptic technology. Many of the components built into the Innosept Asbofill ESL thus correspond to those which have been in use for many years in tried-and-tested Innosept Asbofill ABF linear filling equipment.
    The Innosept Asbofill ESL is extremely flexible in its range of applications. Milk, mixed milk, coffee and yoghurt beverages, fruit juices, and teas – in other words, all types of beverage sold through the cold chain – can be bottled using ESL technology. It can also process products containing pulp and/or chunks. The same flexibility is shown in the range of plastic containers that can be filled here; quadratic, rectangular, and oval bottles can all be processed, the only requirement being that the size of the neck ring is identical.
    As with aseptic systems there are two types of machine available for ESL products. While the Innosept Asbofill ESL 611 has a throughput of up to 12,000 plastic bottles holding between 0.1 and 0.75 liters per hour, the Innosept Asbofill ESL 711 fills 0.25 to 2.0-liter bottles at the same rate. Both of these ESL machines can also be supplied in the TWIN version. Here, instead of investing in two single machines the TWIN doubles capacities while cutting costs, as many of the components central to the system are implemented just once in this concept.
    One of the chief advantages of the Innosept Asbofill ESL is the exceptionally small size of the sanitary room, this being 0.7 m³ in the ESL 611 and just 1.2 m³ in the ESL 711. This in turn has the benefit of cost-effective maintenance and fast cleaning. The sterilization, filling, and sealing processes take place in different housings, with a partition separating the different areas. Bottles and caps are sterilized according to the process of dry sterilization.
    The plastic bottles are filled in the classic manner using two-stage, free-flow filling valves, into which pulp nozzles can be integrated if required. This all takes place under the best possible hygienic conditions, since the bottle mouths are not pressed and sealed against the filling valves during filling. Precise fill levels are ensured by the principle of volumetric, electromagnetic induction flowmetering. If products containing chunks are to be processed, a separate dosing unit can be incorporated upstream of the free-flow filler. Both seals and screw caps can be applied as closures. Even if only one of the above closure systems is selected, as is usual, both modules can be optionally fitted into one machine.
    All told, the new, extremely compact, operator-friendly Innosept Asbofill ESL series of machines not only gives customers top product safety and reliability but also extremely high flexibility with planned product changeovers.
    (KHS GmbH)
    05.12.2012   Completely satisfied - Hirsch Brauerei Honer all set for more sales success with new KHS turnkey lin    ( Company news )

    Company news Picture: Innofill Glass DRS ZMS

    “You can rely on KHS – both for technology and service,” says Rainer Honer, managing director of Hirsch Brauerei Honer. And Honer knows what he's talking about, as he’s been working with KHS since he took over the brewery from his father in 1960. The most recent investment has made one machine out of two, with the tasks of the classic glass bottle and clip-lock bottle lines being integrated into just one KHS turnkey line. “The setup works perfectly – as we expected it would,” smiles Honer. “Our new KHS equipment is very flexible – and at the same time extremely sustainable.” Plant manager Thorsten Jauch adds, “Besides improving the filling quality, it also gives us even better line efficiency.”
    Honer and Jauch are especially proud of their new Innofill Glass DRS-ZMS filler. Jauch states, "I believe this to be the most up-to-date filler technology on the market at the moment.” Incidentally, where the DRS-ZMS filling system is used, KHS ensures outstanding oxygen values of 0.02 mg/l of beer – a value that in practice is often much lower. According to the acceptance results issued by the Technical University in Munich and Weihenstephan, thanks to the new filling system oxygen pickup in beer at Hirsch Brauerei Honer is a mere 0.008 mg/l.
    With its recent investment the brewery from the region for the region is all set for further sales success. In the next few years Honer is reckoning on a moderate increase. “In the last few years a small plus in sales meant that we were already much better placed than the rest of the brewing industry in Baden-Württemberg.”
    As a regional brewery the company enjoys a very good reputation. Under the motto “The gold of our homeland” only local, first-class raw ingredients are used. The brewery also sponsors many local cultural and sporting events, and has promoted the development of tourism by investing in the Mahlstetten adventure park. The most recent activity was to open the brewery’s own woodland climbing course. “We really enjoy getting new things going in the region that secures our existence as a family brewery,” Honer explains.
    Today, Hirsch Brauerei Honer sells 80,000 hectoliters of beer and 30,000 hectoliters of soft drinks per year. In the beer segment Weizen or wheat beer is most popular, amounting to 35% of total sales. This is followed by pilsner, Gold, and many seasonal specialty beers. Impartial organizations have confirmed the high quality of Hirsch beer on several occasions; for example, in 2010 the German Agricultural Society or DLG made Hirsch Brauerei Honer Brewery of the Year. Just recently, the same association awarded Hirsch eight gold medals and one silver medal for its nine submitted beers. The company has also picked up several prizes at European Beer Star, with the Sport Weisse brand winning gold no less than five times.
    (KHS GmbH)
    19.11.2012   Mark of distinction for KHS Innofill Glass filler platform    ( Company news )

    Company news Innofill Glass DRS-ZMS selected for Pack Innovation area at Emballage 2012 trade show

    The success story of the Innofill Glass platform system, which recently launched the next generation of KHS glass bottle fillers, continues. At the Emballage 2012 trade show the Innofill Glass DRS-ZMS is to be presented in the special Pack Innovation exhibition area. A jury of trade journalists specifically elected the innovative filler concept, equipped with the computer-controlled, DRS-ZMS pressure filling system for beer and soft drinks, to be included in this exclusive section of the show thanks to its extensive range of customer benefits.
    The platform-based machine concept convinced the jury with its optimized hygienic design and a whole host of other plus points. These include enhanced filling quality and line availability through short cleaning times, and reduced costs for maintenance, power, water, and cleaning agents.
    The platform system has been carefully planned right down to the last detail. Its special features include the lightweight construction of the lift cylinder table and tubular ring bowl, the lack of front table, the utilization of modern, wear-free, and lubrication-free components, media feed through hygienic, height-adjustable pantograph joints, easy-mount, compact filling valves, tool-free and thus exceptionally fast format changeovers, a compact, space-saving valve manifold, and targeted simplification yet a lower consumption of water and electricity through implementation of the vacuum pump module concept.
    Because the system's energy consumption is so outstandingly economical, KHS has received the Energy-efficient System Technology certificate from the independent TÜV SÜD certification authority for its new Innofill Glass DRS-ZMS. Compared to conventional solutions the system now being presented saves approximately 40% on electric drive power consumption and up to 40% on electric power for the vacuum pump, depending on the operating point.
    The KHS Innofill Glass DRS-ZMS filler series has already proved itself in practical use, with the expected sales figures considerably exceeded within a very short space of time. Countless breweries and soft drinks bottlers worldwide are already relying on this innovative concept. The wine, sparkling wine, and spirits industry has also recently begun to profit from the many advantages of the Innofill Glass, as in it they now have a technical base on which a variety of electronic KHS filling systems can be founded.
    (KHS GmbH)
    15.11.2012   China Brew & Beverage Exceptionally Successful for KHS    ( Company news )

    KHS' participation in the China Brew & Beverage (CBB) trade show in Beijing was a complete success. According to Werner Gessner, head of Market Zone Asia Pacific, "We greeted familiar faces and welcomed new customers at our booth. The great amount of interest in KHS confirms that we are considered a preferred provider in China."
    The CBB, an international trade show for brewery and beverage technology, is considered a major trade event in China and Asia and is held every two years in Beijing.
    The Innofill DPG-ZMS on exhibit at KHS' booth was accorded much attention. The Innofill DPG-ZMS is a short-tube filling system that uses return gas tubes to determine fill levels. When filling beer in glass bottles, the pressurization and filling processes of the Innofill DPG-ZMS are preceded by triple-evacuation and double CO2 purging. There is no pre-evacuation process when bottling beer in PET. The low-oxygen filling process of the filling system presented specifically uses less CO2 and retains high product quality and at the same time offers economical production and maximum flexibility.
    Norman Gras, sales manager in China, says, "KHS filling technology has always been the first choice for a great number of Asian beverage plants. This fact was confirmed once again at the trade show. Even our first order received during the CBB was for an Innofill DRS-ZMS/ZDS draft beer filler. This filling system is already in operation exceptionally well at numerous breweries throughout Asia thus providing positive word-of-mouth advertising in the market."
    (KHS GmbH)


    Company news Petainer, the specialist PET engineering business who have developed a highly innovative and successful range of PETainer one-way kegs (from 15 to 30 litres) for the beverage industry, announces a strategic alliance in Italy with Eminence s.r.l. located in Treviso, for the servicing of the wine and craft brewing sector. Eminence along with KHS will represent as agents the direct sales activities of PETainer.

    Eminence s.r.l. is well known in the local wine branch with long term relationship for international exports will market the product in the Italian territory throughout their network of agents and will organize a logistics base in the north of Italy for Petainer kegs.

    Diego Pistellato owner of Eminence s.r.l. explained: “We have a tremendous demand for red, white and sparkling wines but also craft brewed beers in the Petainer keg format. This is predominantly driven by the growing Italian export market, but also niche domestic sectors.
    “We have been evaluating and testing the Petainer keg for a number of months” says Luca Serena, Managing Director at Vinicola Serena. “Petainer offers significant economic and environmental benefits for our products. It will help us increase sales volumes and penetrate markets where it is difficult or expensive to use standard kegs for example to the US. ”

    Joerg Lauer, Global Sales Manager of Petainer says: “The partnership with Eminence and the close local presence for Petainer keg products marks a significant step in Petainer’s development of the important Italian market. The new one-trip Petainer keg will provide many new market and export opportunities also for smaller and medium sized wine and beer producers."

    The kegs come in three sizes -15, 20 and 30Litre which will provide packages suitable for many export and domestic solutions. More importantly the package is compatible with existing trade dispense equipment and very cost effective compared to the alternatives on the market."
    KHS is Petainer’s international cooperation partner and preferred supplier of filling and handling equipment as well as machine conversion specialist for steel keg lines.
    (Petainer UK Holdings Limited)
    01.10.2012   Petainer and Sovereign Beverage Company Announce Investment in UK Breweries    ( Company news )

    Company news Petainer, the specialist PET engineering business who developed a highly innovative and successful range of one way kegs (from 15 to 30 Litres) for the beverage industry, is represented in the UK & Ireland by Sovereign Beverage Company.

    Sovereign Beverage Company has, in partnership with Frederic Robinson Ltd. and Thomas Hardy Ltd, recently invested in bespoke “PetBoy F2” filling machines, manufactured by KHS GmbH. These machines will shortly be installed at the breweries, in the north west of England, and will provide 0.5M kegs per annum of embedded Petainer capacity to the UK.

    Dan Unwin, Commercial Director & Brew Master of Sovereign Beverage Company explained: “we have a tremendous demand for ale, lager and cider in the Petainer keg format. This is predominantly driven by the export market, but also niche domestic sectors. The installation of KHS “PetBoy” filling machines will provide us with capacity to produce the “Classic” 20 & 30L Petainer, at the same time ensuring optimum product quality.”

    Each “PetBoy” machine houses two independently operating filling heads, ensuring the best product quality and filling results. Fill volume is accurately controlled by a metered filling system, minimising product loss. Each machine provides exceptional process reliability and the utmost product safety.

    “We have been evaluating and testing the Petainer keg for a number of months” says Graeme Hall, Operations & Packaging Manager at Frederic Robinsons Ltd. “Petainer offers significant economic and environmental benefits for draught ale. It will help us increase sales volumes and penetrate markets where it is difficult or expensive to use standard kegs.”

    Andy Carter, Regional Sales Director of Petainer says: “The investment in bespoke filling equipment for Petainer products marks a significant step in Petainer’s UK development. The modular design of the KHS equipment also means production can be quickly expanded and production costs reduced further as demand grows. Together, we have created superb filling facilities to continue the success of our innovative keg systems.”
    "The new one trip Petainer keg filling capacity will provide many new market opportunities for us and all our contract package customers" said Gary Todd, Director, Thomas Hardy Burtonwood Ltd.
    The kegs come in three sizes -15, 20 and 30Litre which will provide packages suitable for many export and domestic solutions. More importantly the package is compatible with existing trade dispense equipment and very cost effective compared to the alternatives on the market."
    (Petainer UK Holdings Limited)
    27.09.2012   Optimized KHS Innopack Kisters Basic Series with Plenty of Added Bonuses    ( Company news )

    Company news With the Innopack Kisters Basic packaging machine now in its new, optimized form, companies in the beverage, food, and non-food sectors who opt for a shrink, tray, or pad shrink packer in this series are set to gain from a whole range of added bonuses. The buzz words here are: greater ease of operation and more flexibility, less energy consumption and lower costs, and increased machine availability.

    The many benefits are as follows:
    In the Basic series, identical servo motors with integrated servo controllers are now used for all function units. This reduces and eases spare part stockkeeping considerably. The individual servo motors are linked to one another through a bus system, with the result that there are now fewer cable connections to the switch cabinet.
    Another major advantage of the optimized machinery is the cubic design of the machine frame. This means greater ease of operation, as there is now more space within the machine. The see-through sliding doors constructed according to hygienic design specifications provide an extremely good view inside the machine even during production.
    A new film cutting and feed system in the film wrapping station has also been designed for specific savings in film. Even films just 25 µm thick are perfectly processed. The servo-driven film cutter ensures much more precise film cutting with less wear.
    There are also many new features in the shrink tunnel area. Optimizing the heating chamber and introducing new ventilators that work extremely efficiently have resulted in an improved flow principle that permits energy savings of up to 20%. An energy-saving package can also be incorporated into the shrink tunnel concept that enables consumption to be cut by a further 20% maximum. This package includes a roller shutter system at the infeed and discharge openings of the shrink tunnel and a standby function. Roller shutters that close automatically bridge downtimes and prevent thermal energy from escaping. Another optional module is an automatic cleaning system for conveyor chains in the shrink tunnel area. Customers can also choose between electric or gas heating for the shrink tunnel.
    Last but not least, the machine's increased flexibility deserves a special mention. In order to cope with frequently changing packaging specifications, the shrink packer can now be converted into a tray packer or pad shrink packer, for example. Adding extra modules to the packaging concept, such as a leaflet inserter or perforation station, is also possible.
    As at present, KHS' Innopack Kisters Basic packaging machines will continue to be suitable for the low-capacity range of 30 to 70 cycles per minute. The individual containers may range in diameter from 55 to 110 millimeters and in height from 110 to 350 millimeters. For product group formations, lengths of between 110 and 270 mm and widths from 200 to 540 mm are possible. With a maximum of three lanes, Basic packaging technology is devised for a wide variety of packaging formats.
    (KHS GmbH)
    25.09.2012   98% Market Share for Beer and 60% for Water    ( Company news )

    Company news Picture: Inno PET Blo Fill 01

    Lao Brewery sees KHS as part of its success story and reinvests

    Breweries don't get much closer to their country than Lao Brewery Co., Ltd. to the Lao People's Democratic Republic. This is demonstrated by the fact that with its Beerlao brand Lao Brewery has a 98% share of the beer market in its native Laos. This share amounts to a consumption of 30 liters per head per year – with the figure at 83 liters for the capital of Vientiane – even though the average per capita income for Laos is just € 820 per annum.
    Over the past few decades KHS technology has been part of Lao Brewery's persistent success as the brewery for the country and its people, which helps to finance comprehensive social projects. The company first invested in a keg line from KHS in the early 1990s. Successive investments in four turnkey glass lines were to follow. The oldest is now 20 years old and, thanks to regular servicing by KHS specialists and the sole use of original KHS spare parts, it's still in top working order.
    Kissana Vongsay, the managing director of Lao Brewery Co., Ltd., explains why, on making his most recent purchase, it had to be KHS yet again. "Right from the start we've had nothing but outstanding experience both with KHS engineering and KHS' services. For us, KHS is simply a first-class company. When it came to investing in a new turnkey PET line for water, as always only the best was good enough for us." The brewery has been active in the sale of bottled water since 2000. With its Tigerhead brand, 60% of the Lao water market is in the hands of Lao Brewery. For the future Vongsay is reckoning on a yearly plus of 30% in its water segment. By 2015 this would mean that the sales figures for water would be almost half of those for beer.
    So that it is fully equipped to cater for the growing demand Lao has invested in a water line that can output 45,000 0.6 and 0.35-liter, and 20,000 1.5-liter PET bottles per hour. KHS provided the plant with plenty of advice on the necessary technology, for instance on the design of the bottles and labels. An InnoPET BloFill monoblock forms the heart of the line, comprising an InnoPET Blomax Series IV stretch blow molder and an Innofill NV filler. Further system highlights are an Innoket 360 labeling machine with a tamper-evident seal applicator, an Innopack PPZ packer, and an Innopal PBL1N1 palletizer.
    For the future Lao Brewery is planning to branch out in several new directions. For example, they are considering including juice, energy drinks, tea beverages, and flavored waters etc. in their product portfolio. Specialties such as beer with a cherry or strawberry flavor for a young target group are also destined for market.
    (KHS GmbH)
    31.08.2012   Petainer UK and Sovereign Beverage Company Announce Strategic Alliance for the UK & Ireland    ( Company news )

    Petainer, a specialist PET engineering business ( who developed a highly innovative and successful range of one way kegs (from 15 to 30 Litres) for the beverage industry, has joined forces with Sovereign Beverage Company in a strategic alliance to develop and strengthen the market in the UK & Ireland.

    “Along with the support of KHS, who produce a range of specialised filling and handling systems for the Petainer keg, we have created a formidable team to continue the success of our innovative keg systems” says Regional Sales Director Andy Carter.

    With Sovereign’s unique network, and knowledge of both the beverage industry and the import / export business, it brings together our complementary skills to further develop the one way PET keg market.

    The Petainer keg offers significant economic and environmental benefits to the beverage industry and is aimed at replacing the current steel based systems in many applications.

    David Davies, Chief Executive of Sovereign says: “We have researched the one way keg market for some time and have concluded that the Petainer keg is best placed to transform the bulk packaging of beverages. This paradigm shift is akin to the replacement of the wooden barrel by the steel keg. We are especially excited about the launch of new formats later in the year which will only serve to enhance the Petainer offering.”
    (Petainer UK Holdings Limited)
    25.07.2012   Flexibility Through Standardization: Six KHS can packaging lines for the production of identical ...    ( Company news )

    ...pack formats

    Carlsberg has a wish of making all of its pack formats for cans sold in Northern and Western Europe producible at all of the Carlsberg sites in these parts of Europe. The reason for this is that production orders then can be flexibly distributed among the various Carlsberg plants according to requirements.
    KHS has met the brewery's demand by supplying technical turnkey systems to several Carlsberg Group facilities, which include not only an Innopack Kisters SP Advanced shrink packer, but also an Innopack Kisters TSP Advanced tray shrink packer, and a KHS Innopal PB 1 HS palletizing system with integrated robot grouping.
    Peter Nilsson, Carlsberg´s former supply chain director for Northern Europe, now VP Customer Supply Chain Europe, says, "KHS has devised standardized packaging systems for each site which take the requirements of each existing canning line into perfect account. We're pleased with them also after commissioning. KHS has also and still is providing us with a full consultancy package, which we are greatly benefitting from." For example, numerous tests were carried out on the various packaging materials and the stability of the required packs at the KHS plant in Kleve. KHS also specially organized packaging workshops for Carlsberg employees, where it not only passed on important expertise and information relevant to the current project but also discussed future possible developments. One of these was the new KHS shrink pack without bull's eyes (the FullyEnclosed FilmPack™), a new development Carlsberg immediately brought into play at its Fredericia site. The Innopack Kisters TSP Advanced at this plant includes a manipulation unit which enables both classic shrink packs and also fully enclosed film packs to be manufactured. At the moment Carlsberg is testing the new packaging option on the Danish market. If the response proves positive, this unit might also be fitted into the Innopack Kisters TSP Advanced at Kerava and Gjelleråsen. "Apart from the high level of stability this type of packaging has, what's important with the FullyEnclosed FilmPack™ is that it offers us a concrete savings potential, as we can now do with pads instead of the cardboard trays we used to need", says Nilsson.
    As follow-up orders prove, Carlsberg is highly satisfied with the KHS packaging setups at its three Nordic plants. Three practically identical KHS packaging lines, which also fully meet the Carlsberg Group's requirements for a standardized system, have already been ordered for the Carlsberg plants of Okocim in Poland, Saku in Estonia, and Lübz in Germany. "Even with these three new can packing lines, the standardization of our packaging technology is by no means complete for Carlsberg", states Nilsson. "In the end, what we're concerned about is that we can provide our customers with the attractive packaging options they require – anytime and anywhere."
    (KHS GmbH)
    19.07.2012   Focusing on sustainability - KHS is a partner in the VDMA Blue Competence sustainability initiative    ( Company news )

    As a member company of the VDMA (German Engineering Federation), KHS GmbH, internationally active manufacturer of filling and packaging equipment for the beverage, food, and non-food industries, supports the Blue Competence sustainability initiative.
    For KHS, sustainability has always been an essential part of development and production, combined with a high sense of responsibility for the environment and for subsequent generations. Participation in the VDMA Blue Competence Initiative is therefore logical on the one hand, and a duty on the other.

    Quote from the Blue Competence Initiative (
    "By sustainability, we mean the balancing and integration of economic, ecological and social objectives. It is thus about responsibility in a wider sense, for instance for wealth, education and security, the natural world and the economic consequences of globalization, structural change or demographic trends Blue Competence defines credible and resilient sustainability criteria and standards that all those who join the initiative must meet. Blue Competence therefore ensures greater transparency, makes it easier for people to know what they are dealing with and provides certainty – for all those who are looking for sustainable solutions and products or companies that act in a sustainable way."
    KHS therefore not only feels that it has a duty to provide trend-setting technologies which are essential for implementing many sustainability ideas, but also sees itself as a driving force in this field.

    Here are some examples:
    -Compared with conventional systems, the new Innofill Glass DRS-ZMS pressure filling system can save up to approx. 40% electrical drive power – TÜV-certified for Brau Beviale 2011.
    -Energy cost savings of up to 50% and a reduction in CO2 emissions of up to 60% are possible in Innopack Kisters packaging machines with the version of the shrink tunnel that uses gas heating instead of the usual electric heating.
    -Compared with the previous generation, a reduction in energy consumption of up to 25% is achieved with the new InnoPET Blomax Series IV generation of stretch blow molding machines. Preforms can be optimized down to the last tenth of a gram of PET material thanks, among other things, to the servo-motor-controlled stretching process.
    -Or Petainer Kegs: these competitively priced, non-refillable kegs, for which KHS supplies filling and packaging systems in the form of the Innokeg product range as part of a collaborative venture, are 100% recyclable. Compared with the classical steel keg version, less cleaning agent is required, transport distances and therefore logistical and storage costs are reduced, and there are no repair costs whatsoever.

    These innovations are examples of the systems and solutions which are already used by KHS today as part of its environmentally conscious and resource-conserving approach. As a partner company in the Blue Competence Initiative, KHS once again underlines its expertise as a provider of sustainable, environmentally friendly, market-oriented and technically leading technologies.
    (KHS GmbH)
    16.04.2012   New generation of Innosept Asbofill ABF aseptic linear filling machines are a great success    ( Company news )

    Company news New option: Processing of plastic bottles with 28 mm neck

    With the new generation of Innosept Asbofill ABF aseptic linear filling machines, KHS has scored a further market success worldwide. In addition to the Innosept Asbofill ABF 611 (output 12,000 0.1-l to 0.75-l bottles/h) and Innosept Asbofill ABF 711 (output 12,000 0.25-l to 2-l bottles/h), the "Twin Concept" which doubles the machine capacity is also popular here. Innosept Asbofill ABF technology manages the aseptic cold filling of non-carbonated non-alcoholic beverages using the dry sterilization method. The focus here is on milk and yoghurt beverages as well as fruit juices, fruit juice beverages, sports drinks, near water beverages, tea and coffee as products to be filled.
    The tremendous interest in innovative Innosept Asbofill ABF technology is thanks to the fact that, with this process, maximum aseptic safety goes hand-in-hand with a very low sterile room volume. While the Innosept Asbofill ABF 711 has sterile zones of just 1.5 m³, a sterile room volume of only 0.9 m³ is required for the Innosept Asbofill ABF 611. A factor which is of decisive importance for maximum aseptic safety is that bottles are conveyed through the machine in just one holder. Aseptic risks, which can occur with conventional switching from one carousel to another, as is the case in the rotary system, are no cause for concern here.
    A practice which has previously been implemented in Innosept Asbofill ABF machines is that only bottles with a neck diameter of 38 mm have been processed. With the new generation of Innosept Asbofill ABF machines, KHS now offers the option of processing 28 mm neck diameters in order to best satisfy market requirements. A decision on the required neck size is made at the same time as the decision to invest in the machine. Additional security is provided in that, if it should be desired at a later date to change from the 38 mm neck to the 28 mm neck - or vice versa - this can be quickly implemented on the machine with a simple conversion. Such a conversion is also conceivable with Innosept Asbofill ABF machines of the new generation which have already been installed.
    The processing of bottles with 28 mm neck is of utmost importance for the fruit juice sector. From a regional point of view, the 28 mm neck is particularly popular in Asia. Discounters worldwide like to sell plastic bottles with this neck size. The option available for the new Asbofill ABF generation of "placing a drop of liquid nitrogen in the head space of filled plastic bottles" ensures the stability of the bottle. Examples of other options which are available for the latest generation of Innosept Asbofill ABF machines and which can be fitted retrospectively if required are the integration of pulp nozzles into the filling valves, nitrogen flushing before the filling process, double filter instead of single filter units in the valve manifolds, and coding within the production process.
    With the new generation of Innosept Asbofill ABF machines, sterilization of the bottles with H2O2 is generally followed by transferring them to the filling station, which is separated from the sterilization process by an intermediate wall. The filling process, which is based on the volumetric filling principle, is carried out without contact by two-stage free-flow filling valves. For sealing the bottles, a choice can be made between screw caps and seals. Like the sterilization of the bottles, the sterilization of the caps is also carried out with H2O2.
    As a next step, KHS plans to design the Innosept Asbofill ABF machines of the new generation in such a way that 28 mm necks and 38 mm necks can be processed with just a short changeover time. An appropriate conversion option will be provided for Innosept Asbofill ABF machines already on the market. Also planned is the development of an Innosept Asbofill ESL (Extended Shelf Life) version for non-carbonated non-alcoholic beverages in plastic bottles which are sold via the cold chain.
    (KHS GmbH)
    08.02.2012   Innoket 360 S Labeling machine - Trend-setting roll-fed system with slim-line design    ( Company news )

    Company news Modern roll-fed labeling machines from KHS are complete solutions. This cost-effective labeling solution is our answer to the constantly increasing demand for reliable labeling of high-quality wrap-around labels for cans, glass bottles, and PET bottles. They cut your labels to the exact length you require, and, thanks to self-sharpening knives, ensure high levels of operational safety as well as constant cutting precision. With just a minimum amount of hot glue, the cut label is applied to the rotating container and glued, overlapping perfectly. With a compact but extremely functional design, this labeling solution protects not only your budget but also the environment.

    Good to know
    The Innoket 360 S is the logical development of our successful Innoket 360 labeling machine. The difference is a significantly slimmer, tremendously space-saving design at the same capacity of 50,000 bottles an hour. With the Innoket 360 S, you can label the PET bottles typically found in the soft drink and mineral water sectors as well as other container materials, with high-quality wrap-around labels.

    Well thought out
    The future-proof design of each module makes it possible to expand this labeler as required and therefore tailor it to your individual requirements.
    With this innovative system solution, we help you to lastingly save on resources during ongoing operation - for the service life of the machine.

    -Modular design for maximum flexibility
    -Exact temperature control
    -Overlap correction for top labeling precision

    -Effortless processing of cutting-edge labeling materials
    -Standard induction heating for efficient use of energy
    -Intelligent auto splicer technology without continuous consumption of compressed air results in a saving of more than 80%
    (KHS GmbH)

    03.01.2012   New KHS label lab offers an extensive range of benefits    ( Company news )

    Company news Fine feathers make fine birds – and fine labels make fine containers! Yet however professionally beverages are produced and filled, if the label's wrong, the consumer is very hard to convince about the product at the point of sale. This goes to show just how important a role the perfect labeling of beverage bottles has to play in the success of a company.

    The interaction of several factors in the labeling process has a decisive influence on the overall result, these being the labeler, label adhesive, labels, and of course the nature of the bottles to be labeled. KHS provides comprehensive advice on the optimum symbiosis of the above factors. In order to provide maximum service in this respect, KHS recently set up an in-house label lab which examines the various properties of labels using state-of-the-art measurement devices.
    The label lab at the KHS plant in Dortmund, Germany, is best equipped for the study of all kinds of label, from conventional cold glue paper labels through self-adhesive labels to film labels and roll-fed labels. At the lab all labels are tested in full detail under ideal test conditions, i.e. at a temperature of 23°C (+/- 1°C) and at 50% humidity (+/- 2%).
    When a KHS labeling machine is purchased, in the label lab KHS checks whether the label and ordered labeling technology are fully compatible with one another. At the same time KHS provides advice on the ideal storage and processing conditions for the labels in question (for example on the optimum humidity and air temperature in the plant). Should labels be changed during the service life of a KHS labeler, KHS customers can again refer their new label designs to the label lab at any time, where they will receive sound and expert advice.
    Another advantage of the new label lab for the customer is that it provides access to a database which is currently being extended. Based on statistics gleaned from experience, this database enables reliable prognoses to be made as to the effect of certain label properties on the quality of a label.
    Yet another outstanding advantage is that the latest industry research is also being applied to KHS label testing. To this end KHS maintains close contact to various research institutes and label manufacturers, engaging in a permanent exchange of information and experience. This is just one of the prerequisites for KHS being able to advise clients on the sustainability of their label designs. To sum up, the new KHS label lab allows KHS to provide customers worldwide with a full consultancy service on all aspects of labeling based on a holistic approach – giving clients the maximum benefit.
    (KHS GmbH)

    15.12.2011   Certificate from TÜV SÜD    ( Company news )

    Company news "Energy-efficient system technology" Certificate from TÜV SÜD for KHS' New Innofill Glass DRS-ZMS Filler Series

    Sustainable solutions that cut production costs and additionally meet the demand for top quality standards - this is what the beverage industry is calling for when investing in new bottling and packing technology. A large number of both big corporations as well as SMEs in the beverage industry have "taken up the cause" of drastically reducing the power and water consumption in production, in some instances by more than 20 percent.
    To meet these demands of our customers, the factor of sustainability is given top priority in all new KHS developments. KHS will also be communicating this basic principle at the Brau Beviale trade show, where it will be ringing in a new generation of platform-based bottling machines for glass bottles, the Innofill Glass series. This new generation is aimed particularly at sustainability. The Innofill Glass DRS-ZMS pressure filling system now being presented, for instance, saves approx. 40 percent on electric power consumption and, depending on operating point, up to 40 percent on electric power for vacuum pumps compared to conventional solutions.
    Because the new system is so economical when it comes to energy, KHS will be receiving the coveted "Energy-efficient system technology" certificate from TÜV SÜD at Brau Beviale for its new Innofill Glass DRS-ZMS. KHS purposely chose the TÜV SÜD certifying organization because it is an independent certification authority that also enjoys the highest recognition internationally.
    Dr. Michael Bunk, Head Auditor of TÜV SÜD says, "We are always very gratified to see worldwide companies like KHS giving such high priority to sustainability and genuinely putting life into energy efficiency, which all too often is no more than an empty phrase."
    Professor Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH states, "With our new Innofill Glass generation of bottling machines, we at KHS are once again demonstrating our innovative capabilities and at the same time setting a new standard for the beverage industry. Our Innofill Glass series offers customers an up-to-date, sustainable solution that, along with its many specific advantages in terms of operating and maintenance, also reduces energy requirements and saves operating costs at the same time. What is more, our developers are already on track to come up with new product innovations to lower operating costs sustainably and generate yet more added value for our customers."
    (KHS GmbH)
    20.10.2011   KHS in-house exhibition with 100 participants a resounding success    ( Company news )

    Company news "Our innovations just keep on coming" - this was the motto of the KHS in-house exhibition which was held at the KHS Bad Kreuznach site in September. 100 participants from the beverage industry took part in the event. As well as the non-alcoholic beverage industry, the brewing industry and the wine, sparkling wine and spirits industries were also represented. The objective of the participants was to find out more about KHS innovations and to experience the competitive advantages in detail.
    At the center of the event was the newly developed Innofill Glass range of KHS fillers for glass bottles. This is an innovative, platform-based machine concept with which KHS is introducing a new era of filling technology. Innofill Glass is characterized by a consistent implementation of hygienic design. Companies in the beverage industry benefit from the new system as a result of increased filling quality, reduced energy, cleaning media and water requirements, and minimized maintenance. Advantages, which also include increased system availability. Ludwig Clüsserath, Manager, Filling Technology Competence Center, says, "The first KHS filling system established on the market to profit from the innovative KHS Innofill Glass platform system is the computer-controlled, pneumatic Innofill DRS-ZMS pressure filler which is predestined for the bottling of beer. The next step is to adapt the setup for further filling systems from KHS for soft drinks, water, wine, sparkling wine and spirits. Wernesgrüner Brauerei will soon be the very first brewery to benefit from the Innofill Glass DRS-ZMS. The system will be incorporated into a new KHS line there, and will fill up to 50,000 glass bottles/h."
    The way in which the brewing industry views the Innofill Glass system was illustrated at the event by Thorsten Jauch, Engineering Manager of Hirsch-Brauerei Honer. He has been intensively involved with the new development, as Hirsch-Brauerei Honer is one of the pioneers, and has already ordered the Innofill Glass filling system. Thorsten Jauch comments, "On the one hand, we see the comprehensive package of advantages that are a feature of the Innofill Glass. On the other hand, we were so satisfied with our previous 30-year-young KHS filling system that it just had to be another KHS system this time round."
    Professor Dr.-Ing. Matthias Niemeyer, CEO of KHS GmbH says, "With the Innofill Glass, and with many other innovations, we at KHS are quite specifically demonstrating a high level of innovation and systems expertise. Examples include the newly developed Innopro ECOStab beer stabilization system, the compact Innokeg Till CombiKeg keg sanitizing and filling machine, and also shrink packing without shrinkage holes."
    The participants were unanimous in their summing up of the event: an in-house exhibition which was more than worth taking part in. What is more, the industry will also be trusting KHS to keep innovations coming in the future. Prof. Niemeyer comments, "At KHS, we are striving for technology and service leadership. Our great innovative strength is an important foundation for this - in the interests of our customers worldwide."
    (KHS GmbH)
    12.10.2011   Innopro ECOStab Rings in New Era of Stabilizing Beer    ( Company news )

    Company news With its Innopro ECOStab, KHS is ringing in a new era of stabilizing beer. The Innopro ECOStab invalidates the view currently held in the brewing sector that regenerative beer stabilization using PVPP is only economically viable at a beer output of more than 400,000 hectoliters per year.
    The modular Innopro ECOStab is just as suitable for small and medium-sized breweries as it is for large breweries. Three versions of this innovative system are available. Operators can choose between stabilization outputs of 200, 400, and 600 hectoliters per hour. The 200-hectoliter model features three stabilizer modules, each with one column, the 400-hectoliter model has three stabilizer modules with two columns each, and the 600-hectoliter model has three stabilizer modules with three columns each. In addition to the modules, each Innopro ECOStab system has a PVPP dosing tank and a regeneration unit.
    By comparison with horizontal screen and gap candle filters previously used for regenerative beer stabilization using PVPP, the Innopro ECOStab significantly reduces the cost of investment. At the same time, the short production cycles of the individual stabilizer modules and the particularly small container volume required for the Innopro ECOStab reduce the required PVPP volume by half, resulting in significantly lower PVPP material costs. Moreover, the Innopro ECOStab can be used with any PVPP material available on the market, irrespective of the manufacturer. Further benefits resulting from the small container volume chosen for the Innopro ECOStab include comparatively shorter setup times for system startup and shutdown, minimized switching times between different beer styles and reduced blending amounts when changing beer styles.
    Because the Innopro ECOStab operates with several redundant system components it achieves continuous output and enables 24/7 operation. This is particularly beneficial if the unit is used downstream of a continuously operating crossflow filtration system.
    Another important aspect in favor of the Innopro ECOStab is that it has an easily manageable filter surface for convenient and reliable cleaning. Since the Innopro ECOStab uses a stabilization process that always works from inside to outside, which means that PVPP can only be found inside the stabilizer modules, a jet cleaner reaches all surfaces reliably. Manual cleaning is no longer required, resulting in high system availability.
    The Innopro ECOStab has container dimensions and can easily be transported as a single unit, so that commissioning at the brewery is very quick, based on the Plug & Produce principle.
    (KHS GmbH)

    04.10.2011   New Era of Filling Technology Dawns - Innovative KHS Innofill Glass filling system offers...     ( Company news )

    Company news ...extensive range of benefits

    With the newly developed platform system Innofill Glass, international manufacturer of filling and packaging equipment for the beverage, food, and nonfood sectors KHS is launching a new era of filling machines for glass bottles. The new platform provides a technical basis for various electronic KHS filling systems that can be tailored to suit the individual criteria of specific filling methods. The first KHS filling system established on the market that is compatible with the innovative platform system Innofill Glass is the Innofill DRS-ZMS pressure filling system, predestined for the bottling of beer. More KHS fillers for beer, soft drinks, wine, sparkling wine, and spirits are soon to be included in the Innofill Glass concept.
    The chief feature of the new Innofill Glass system is the consistent implementation of the Hygienic Design concept. The optimization thereof results in a range of additional benefits, such as consumer protection thanks to increased product safety, and cost reductions through simpler cleaning and maintenance.
    Innofill Glass has an open design with no corners and edges but with curves and slopes, enabling a rapid runoff of liquids. In place of the conventional filler front table a bottle transfer frame connects the stars and capper modules using open pipes with no flanges.
    Low-wear, energy-efficient torque motors, direct drives with an especially high torque and a relatively low speed, are used to drive the transfer stars and the capper. Drives with torque motors have an efficiency of 96%; conventional drive systems are just 85% efficient. At the same time the cost required for maintenance is minimized thanks to an extremely low susceptibility to wear.
    There are no electrical elements, pilot valves, and control hoses in the filling valve hygiene area. Encased in stainless steel housings the electronics and solenoid valves are separated from the actual filling area – an important prerequisite for automatic exterior cleaning.
    The constructional optimization of the new Innofill Glass platform has also lead to a considerable reduction in the number of parts in the filler carousel section. Using finite element calculation a reduction in weight has been achieved while increasing the stability of the machinery. The new system has a compact valve manifold which, compared to the valve manifold previously incorporated, requires 50% less space for installation. Another major new feature is that the filler and capper system can be expanded in modules to include additional cappers.
    The Innofill Glass platform is controlled by the new KHS operator panel with an integrated RFID system which has won several awards, among them the red dot award and iF award. The panel excellently combines ergonomics, navigation, and design. The result is user-friendly operator prompting that makes use of buttons, colored graphics, easy-to-remember icons, and interactive handling instructions – all of which have been kept deliberately simple and are self-explanatory. The system is subdivided into several levels, thus providing access to varying degrees of viewing detail and different operating levels as the specific application requires.
    All told, the innovative Innofill Glass platform system offers an entire package of remarkable benefits. For instance, the hygienic design has been optimized in every conceivable way to enhance the filling quality and line availability while reducing the cost of maintenance, power, water, and cleaning agents.
    (KHS GmbH)

    01.08.2011   Compact Innopro CIP C achieves considerable savings and loses none of its outstanding cleaning capac    ( Company news )

    With its latest CIP system, the Innopro CIP C, KHS has succeeded in developing a new generation of CIP technology which combines the best cleaning results with an exceptionally compact, economical, and maintenance-friendly design. Given advantages like these, an investment in the Innopro CIP C can be regarded as an investment in a future when the watchword "Ecological Footprint" will come into increasingly sharp focus.
    The Innopro CIP C is a locally active CIP system which sanitizes not just the filler and itself but also one other process component, such as the flash pasteurizer or mixer. Equipped with three tanks (primary water feed and a caustic and hot water tank which can also be used as an acid tank if necessary), the Innopro CIP C is a CIP system that can cope with the entire filling operation on its own in medium-sized beverage plants in which there is only one filling line to clean. Companies which have several lines and an extensive pipe system can also exploit the advantages of the compact Innopro CIP C in combination with a central CIP system. Compared to similar systems that use conventional CIP technology, the Innopro CIP C means a considerable reduction in energy consumption thanks to positioning directly next to the filling system, not least because there is hardly any heating loss while the media are conveyed. In addition, media consumption is also reduced as a result of the shorter conveying distance to the components to be sanitized, and fewer mixing stages mean less water and cleaning media are used, too.
    The Innopro CIP C is predestined for use in every imaginable kind of process and filling technology. Whether beer, water, soft drinks, juice, wine, or milk are to be filled into cans, glass bottles, plastic bottles, or kegs, the Innopro CIP C can be integrated anywhere. Moreover, not only can the Innopro CIP C be used in cold filling; it is equally well suited to aseptic filling, ultra-clean filling, and hot filling. The cleaning capacity of the Innopro CIP C is such that it can handle fillers with up to 150 filling valves and a filling output of up to 35,000 liters per hour.
    Another major advantage of the Innopro CIP C is that thanks to the use of rectangular tanks, among other features, it can be packed in one container. The system can be cost-effectively shipped in a standard overseas container.
    All the components needed to operate the system, such as pumps, valves, heaters, media tanks, and the switch cabinet with control, are already arranged and installed ready for operation on a stainless steel framework at the KHS plant. Furthermore, since all the components have already been tested at the KHS plant the Innopro CIP C can be commissioned very quickly at a beverage plant using the Plug & Produce principle.
    (KHS GmbH)
    07.03.2011   KHS Presents Innokeg Till CombiKeg Live for the First Time    ( Company news )

    Company news New, compact keg washing and racking machine for small and medium-sized businesses is excellently received by the industry

    With its Innokeg Till CombiKeg internationally active manufacturer of filling and packaging equipment for the beverage, food, and non-food industries KHS GmbH has developed a keg washing and racking machine that provides small and medium-sized businesses in the brewing, soft drinks, mineral water, fruit juice, and wine sectors in particular with a comprehensive range of benefits.
    In order to communicate these advantages to a live audience, KHS invited representatives of the industry to view the prototype of the Innokeg Till CombiKeg at its plant in Kriftel, the KHS Group's competence center for keg technology. Many companies accepted the invitation, among them German breweries Eichbaum Brauerei, Einbecker Brauhaus, Licher Privatbrauerei, Pfungstädter Privatbrauerei, and Paderborner Brauerei. Companies from outside Germany who participated in the event included private brewery Zwettl from Austria and Czech brewery Strakonice. German brewery Schönbuch was also present, who demonstrated great foresight in reserving the Innokeg Till CombiKeg prototype for its establishment some time ago. Werner Dinkelaker, owner of Brauerei Schönbuch, says, "We are already looking forward to this prototype and are proud to be the first company to profit from the Innokeg Till CombiKeg."
    The event began with a presentation which focused on the extensive activities of the world market leader in keg system technology. This was followed by an explanation of the theory behind the many plus points of the new development, followed by a practical demonstration on the Innokeg Till CombiKeg itself.
    The participants were quite taken by the extremely compact design of the keg washing and racking machine that operates on the principle of rotary processing and is able to output 60 to 90 kegs an hour. They were also impressed by the fact that despite its compact size the Innokeg Till CombiKeg not only washes kegs inside and out, but also racks them, and also has integrated in its cladding all media tanks, controls, and conveyors. The overall dimensions of the Innokeg Till CombiKeg are such that the entire machine fits in a container. It can be fully commissioned in Plug & Produce mode. Another exceptionally beneficial feature of the Innokeg Till CombiKeg is that the system is modular, enabling a great number of possible configuration options. Whether the customer requires three washing heads and one racking head or five washing heads and one racking head, classic return gas control or DFC racking: anything is possible. A wide range of additional equipment can also be added downstream of the keg washing and racking process, such as keg scales, a keg turner, keg capper, camera, et cetera, et cetera, et cetera.
    After inspecting the machine guests were taken on a tour of the KHS Keg Technology Competence Center, giving them the opportunity to gain an insight into state-of-the-art production processes and glean information on KHS' extensive portfolio of keg systems.
    The event ended on a sociable note, with visitors tucking in to various specialties from Hesse. The unanimous verdict of the participants was that the day had been well worth it. What's more, "The Innokeg CombiKeg is just the kind of innovation the market wants, one that combines compact design with the utmost flexibility, ease of operation, and hygiene."
    Rainer Deutschmann, Global Product Account Kegging, KHS GmbH, said of the successful event in Kriftel, "We are tremendously pleased that our new development has met with such positive feedback within the industry. We thus expect great things of the Innokeg Till CombiKeg. We are also delighted that some of the visitors to the event would have liked to have taken the prototype back with them; we even received our first orders for it. We weren't expecting such a spontaneous response. We consider this to be an especially great compliment." (KHS GmbH)

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