Novedades - KHS GmbH

Novedades - KHS GmbH




Novedades - KHS GmbH

Newsgrafik #29467

Brau Beviale Nürnberg 2014  (Brau Beviale)

Visit KHS GmbH at Brau Beviale in Nürnberg, 11-13 November 2014, Hall 5, Booth 147

Newsgrafik #36351

Packaging machine from KHS and Schubert convinces Rotkäppchen-Mumm on all counts  (Company news)

Picture: At the heart of the line is the KHS pick-and-place packer, here being supplied with fruit secco in mini bottles

The quality must be right: this is of paramount importance to Rotkäppchen-Mumm. Accordingly, the demands made of the diverse range of packaging used by the sparkling wine producer are high. In KHS and Schubert the traditional company has at its side two packaging experts with many years of experience. Rotkäppchen-Mumm is now profiting from increased flexibility and capacity thanks to its new system solution.

Rotkäppchen and Mumm are two brands that all Germans are familiar with. Since 1984 the brand with the red cap that lends it its name has stood for sparkling wine from Freyburg in the Saale-Unstrut wine-growing region. In 2002 the East German sparkling wine producer, by then a national market leader, took over brands Mumm and MM, with the sparkling wine for these made by Matheus Müller in Eltville in Germany’s Rheingau.

However, it is a little-known fact that behind these two traditional names lies a whole host of other brands and products. These include various other sparkling wines such as Jules Mumm or Geldermann, brand spirits Chantré, Mariacron, Nordhäuser or Eckes Edelkirsch and wines like Blanchet – products which are produced, filled and packaged in countless variations at seven facilities in Germany and one in Italy.

Big variety in a small space
The range of different packaging required is thus also sizeable, proving something of a challenge for production. “Up until now we needed a separate packaging machine for each format,” explains Lars Grebe, head of Sparkling Wine at the Rotkäppchen-Mumm Enology Competence Center in Eltville. This is where Mumm, MM Extra and Rotkäppchen fruit secco are filled into 0.75-liter bottles and piccolo containers holding 200 milliliters. “Our production site is in the middle of a residential area bordered on one side by the River Rhine. There’s therefore no room to expand,” states Grebe. “As we only have a very limited space at our disposal, it’s imperative that we make efficient use of it.”

The Innopack TLM: one packaging machine for everything
Rotkäppchen-Mumm was also guided by this principle when it began looking for a specialist who could make its packaging area more powerful and flexible in order to satisfy growing market and marketing requirements. Following a long phase of orientation and planning the contract was awarded to KHS. Thanks to KHS’ cooperation with Schubert, the expert for carton packaging from Crailsheim, Germany, as the sole bidder the Dortmund systems supplier was able to master this mammoth task using just one machine.

The plant engineering installed in September 2018 includes 13 sub-machines and is an impressive 33 meters long. This is anything but small, yet the combined Innopack TLM packaging system scores on performance, quality and adaptability on several counts. “Compared to our previous standard we’ve doubled the line capacity for our gift packs of one and two bottles and can now package up to 33,000 bottles an hour,” reports Grebe, who thus far has run the machine in two-shift operation.

Even so, speed is not everything, as he is keen to emphasize. “While a shipping carton of 24 can get away with the odd tiny flaw, we want 100% quality for our gift packs, so there’s practically no leeway here.” After all, the person receiving the gift should have fun unpacking it, for we all know that beautiful wrapping makes a gift all the more enjoyable.

Prepared for the future
The most important criterion for Grebe and his colleagues, however, was flexibility. Whereas on placement of the order there were nine packaging formats listed in the requirement specifications, during commissioning a few more were added, with the machine now processing eleven different types of cardboard packaging. This is by no means the end of the story, however. “I’m convinced that we’re also well able to meet future demands from the retail trade with our new technology,” Grebe says. “One prospective option could be the packaging of 0.75-liter wine bottles, for instance, and also new format sizes, such as packs of three or five.” Another major aspect of the machine’s flexibility is that it has been designed so that only a few format changeovers are necessary and the tools can be switched over relatively quickly. “We convert the machinery a maximum of four times a week. Depending on whether we’re making a hard change from fruit secco to sparkling wine, where we have to change over several transmodule plates, or just switching the heads on the KHS pick-and-place packer, this only takes 30 to 90 minutes,” Grebe happily remarks.

In order to understand how complex the packaging tasks are at Rotkäppchen-Mumm, let us take a look at the individual steps involved when the machine packs individual bottles into gift packs and then shipping cartons, for example. Here, no fewer than ten of the 13 sub-machines are used. On the first two up to 550 cardboard blanks per minute are extracted from the magazines. Robots grip the individual packs that are arranged in a row, erect them and place them on a transmodule which travels through the machine to the next steps in the process. The flaps are glued before the underside is sealed in the next sub-machine and the gift pack is turned upright and placed on a second transmodule segment in rows of two. At the next station the bottles are picked up by the KHS Innopack PPZ pick-and-place packer and carefully placed in the gift packs which are open at the top. The top side of the cartons is then also sealed; next, these are pre-grouped on one of two further transmodules so that they can be packaged for shipping.

Patented transmodules
The last part of the packaging process prepares the goods for shipping. As with the individual packs blanks are also destacked from the magazines for the secondary packaging, erected, glued and placed on their own transmodule segment. In the penultimate sub-machine the sealed gift packs are lifted into the secondary packaging in groups of four by six products at a rate of up to 23 times a minute. In the final station the top of the shipping carton is also sealed.

The various sub-machines are linked by Schubert’s patented transmodules. Thanks to their inductive energy supply and wireless transfer of data and signals they glide back and forth on their rails along the entire line without interfaces. Maximum availability and the best possible efficiency are ensured by a considerable reduction in the number of mechanical parts.

One can imagine that the planning, installation and commissioning of such a complex machine was a huge challenge for all involved. “The time slot for installation was extremely ambitious,” remembers Max Schwaiger, the man responsible for Packaging Product Support at KHS. “Thanks to our good project management we were able to keep to the deadlines. This wasn’t just a matter of course as the growth in the number of formats during the process resulted in a certain level of complexity.” Owing to the limited space at the final place of installation in Eltville the system had to be completely dismantled and brought into the building horizontally. With the help of 3D simulation calculations were also made with millimeter accuracy as to how much space the machine column on the pick-and-place packer would need during erection of the machinery. In a work of absolute precision the ceiling grid only had to be dismantled and cut out at this point.

Result has Rotkäppchen-Mumm convinced
Lars Grebe is delighted with the cooperation between KHS and Schubert. “They make a really strong team. We’d never have come up with the idea of Schubert and its transmodules on our own as we associate these with totally different branches of industry – from pharmaceuticals to candies. Only in conjunction with KHS’ expertise in the beverage sector and particularly in the handling of bottles have we found the perfect solution.” For Rotkäppchen-Mumm one big success factor was also that there was only one point of contact in KHS’ system of project management.

In the meantime the new technology also has the system operators convinced. “Over the years our colleagues of course build up a kind of emotional bond with their old machines which can be ‘knocked back into shape’ with a hammer if need be. The overall function and look of the new machine are so fascinating and convincing, however, that initial skepticism has long given way to total enthusiasm,” Grebe says.
(KHS GmbH)

Newsgrafik #36318

Innoket Neo Flex: KHS presents its new modular labeling machine  (Company news)

-Successor to the Innoket SE launched
-Labeler provides fast conversions and very long service life
-Modular stations for great flexibility

Photo: In the Innoket Neo Flex KHS provides a highly flexible machine that thanks to its modular design manages all of the conventional gluing techniques.

More and more customers are asking for modular systems and solutions. The KHS Group is thus systematically restructuring its engineering portfolio – also as regards labeling technology. Its prime move here is the addition of the modular Innoket Neo Flex machine to its tried-and-tested Innoket Neo series. With its quick-change modules this extremely flexible system masters all standard labeling techniques. Furthermore, thanks to the low maintenance effort and very long service life users benefit from low operating costs.

With its new labeling machine the KHS Group is consistently advancing its modular system design strategy and strengthening its portfolio in uniting the KHS Innoket Neo Flex and KHS Innoket Neo in a single series. This supersedes the previous Innoket SE generation of machines.

Flexibility first
Thanks to the Innoket Neo’s flexible design the individual modules on this highly customizable labeler can be freely combined. Henrik Kahrmann, who works in Product Support at KHS, outlines the benefits. “In the past there was a separate machine for each different labeling technique. This was optimized for its specific area of application but reached its limits when customers wanted to expand their portfolio, for example by adding self-adhesive labeling in combination with the classic cold glue method.”

With the Innoket Neo KHS has developed a machine that can be configured at will thanks to its modular design. The new Innoket Neo Flex goes several steps further when it comes to standardization and meets all customer demands in a single series – regardless of whether with permanently installed stations or as a modular machine. Depending on the machine size and respective requirements the Flex series can be equipped with two to four modules. These are exchanged with just a few manual adjustments performed without tools.
Labeler convincing with its wide range of application

The Innoket Neo Flex also demonstrates great flexibility in the choice and size of container. The machine labels both plastic and glass containers and cans in all of the standard sizes. The output totals up to 74,000 containers per hour. Depending on requirements all further standard capacity ranges can also be catered for.

The flexible Innoket Neo Flex can be used as either a single machine or as part of a production line. “Our labelers have been designed so that they can be easily integrated into any existing or planned line,” says Kahrmann.

Low maintenance and ease of operation
Another advantage of the new modular machine is its extreme ease of operation. With its patented folding door technology the machine carousel and individual stations are readily accessible at all times. Moreover, no additional cladding is required for the area beneath the machine table. In addition, operators profit from bearings lubricated for life that make the labeler extremely low maintenance and reduce the amount of lubricant needed. The new, ergonomic HMI provides great ease of operation. This can be moved by the operator to the required position very simply.

The Innoket Neo Flex is equipped with future-proof TIA technology from Siemens. “The combination of TIA Portal and SIMATIC S7-1500 controller results in significant performance benefits in the control unit’s reaction time,” Kahrmann explains. The labeling machine also has a simplified electronics concept, in which most of the components are installed in the control cabinet. The perfect combination of central and decentralized control calls for much less cabling.

Fast supply of spare parts and consumables
Parallel to the standardization of its machine series KHS has also significantly speeded up the supply of spare parts to its customers. At the same time the supply for all existing machines continues to be ensured without limitation. For optimum operational behavior and low wear KHS provides all of the necessary consumables such as glue and also advises its customers on materials that are difficult to process at its own label laboratory – especially set up for this purpose.
(KHS GmbH)

Newsgrafik #36316

Paper not film: KHS launches ecofriendly can packaging system  (Company news)

-New development as a supplement to film or wrap-around cartons
-Costs cut by lower consumption of materials and energy
-Conversion instead of new investment through adaptation of individual modules

Photo: The KHS Group has added a further environmentally-friendly system to its portfolio. With its tried-and-tested Innopack Kisters tray packers the systems supplier now enables cans of food and beverage to be wrapped in paper.

The new technology provides an alternative to shrink film or wrap-around cartons. Regarding stability the results are the same yet compared to cardboard costs are lower as less energy and fewer materials are used. With a few minor adjustments existing machines can also be converted to the new setup.

The idea of using paper as a secondary packaging is not new; KHS first experimented with this around 20 years ago. “Back then, this technology didn’t catch on, however, as paper was a cost-intensive raw material and wrapping containers in film yielded better results regarding stability,” says Karl-Heinz Klumpe, packaging product manager at KHS. The beverage industry thus opted for different systems and solutions. “Our customers now want alternatives to the usual packaging systems such as film. These should be as ecofriendly as possible,” he continues. To this end, the paper wrapping has now been developed together with an international beverage producer. This type of pack can replace shrink film or wrap-around carton packaging for transportation or sale on packs of 12 or 24 cans in the high-capacity range of up to 90,000 cans per hour.

Few process adjustments thanks to modular machine design
In order to wrap cans in paper instead of film just a few adjustments are needed to the Innopack Kisters tray packer, a machine well established on the market. “KHS is increasingly supplying modular systems and solutions that enable and ease the appropriate conversions to our machines. In this case, we’ve simply reengineered the process module for folding and wrapping,” Klumpe explains. “The standard components such as tray separation from the magazine, gluing or can feed are identical to those on the hundreds of proven KHS machines already on the market.” This allows beverage producers to have the tray packers already in operation at their plants converted simply by adapting certain modules, making a full new investment unnecessary.

Wrapping cans in paper has many advantages over other materials, believes Klumpe. “On the one hand, paper is kinder to the environment than film with respect to ocean pollution, for instance. Paper biodegrades in the environment after a few weeks.” On the other hand, fewer packaging materials are used. Instead of a sturdy wrap-around carton or film packs on trays, packaging cans in thinner paper only needs a flat, stable corrugated card pad as a base – with identical results regarding stability.

Costs are also cut by the new paper pack: compared to a wrap-around carton by up to 15%, with outgoings about the same as for film. Overheads are also considerably reduced by the low energy consumption of about 14 kWh an hour at 80 cycles a minute. The folding process is such that the pack is also fully enclosed. “In contrast, dirt can get into film packs with small side openings. Over long distances especially paper has the clear advantage when it comes to protecting the pack,” Klumpe states.

Great interest from the beverage industry
Klumpe sees huge potential for the new KHS technology. “When I think how much food is canned all over the world, with our paper pack we offer a useful alternative to conventional secondary packaging. With our system we can significantly help to cut down on the amount of plastic waste being generated.” According to Klumpe, this will support the efforts being made throughout the entire sector to protect the environment. “Sustainability is also always a cost factor, however. With our new approach we’re catering for both aspects here.”
(KHS GmbH)

Newsgrafik #36169

Strong signal for Dortmund: KHS invests €20 million in site modernization  (Company news)

-Measures to boost competitiveness
-Automation and digitalization of production processes
-Employees benefit from modernization

The KHS Group has invested €20 million in modernizing its headquarters on Juchostraße in Dortmund, Germany. In a bundle of measures underway since 2015 the company has built a huge, approximately 4,300-m2 production shop and fully renovated another. As one of the world's leading providers of filling and packaging systems for the beverage industry KHS is thus ensuring that it stays competitive in the long term.

Photo: With its new production shop KHS is increasing its production capacities. In an area measuring 4,300 square meters the systems supplier has now merged the relevant technology for container and pack conveyors.

The last construction machines will disappear in the spring, marking the end of the extensive process optimization and other measures at the KHS production site in Dortmund. According to plant manager Dr. Joachim Konrad these were absolutely essential to strengthen KHS’ competitiveness. “As a company active worldwide we find ourselves in a competitive situation and want to carry on manufacturing in Germany. We’ve therefore further digitalized and automated our infrastructure and processes in Production.”

Here, key elements of the modernization included extending the production area and renewing the machine park. At its production site on Juchostraße KHS has erected a completely new production shop. In an area measuring 4,300 square meters the systems supplier has now created conditions that enable the relevant technology for container and pack conveyors to be merged and order processing to become more efficient. KHS has also modernized one of the oldest production buildings on the company premises. With an investment volume of six million euros for this project alone the engineering company has not only renewed the shop floor and roof; it also optimized its Sheet Metal Manufacturing Department housed in the hall, incorporating new technology that includes a faster, more efficient fiber laser, a combined punching/laser machine and a larger, fully networked sheet metal warehouse.

This yields many benefits for KHS customers in the beverage industry, among them leading brands from around the globe. “Demands are becoming more complex. Like when you configure a new car nowadays, we can customize our filling and packaging systems to suit the precise requirements of the respective customer,” states Konrad. “We cater for the huge individualism of each customer with our cleverly compiled, standardized product modules that allow systems to be designed and constructed in automated processes.” Production sequences have again been considerably simplified during the course of numerous optimization measures.

Strong signal to the regional economy
Local employees also profit from the site’s extensive modernization. KHS has now renewed the factory canteen and various office complexes, including the workstations in various company departments. With around 1,200 personnel the company in Dortmund manufactures machines for labeling, pasteurization and bottle washing, among other equipment, plus container conveyor technology for industrial beverage production.

For KHS, the modernization is a big commitment to the production facilities on Juchostraße, says Konrad. “The Dortmund plant is extremely important to the KHS Group, also because of its standing as our international company headquarters. With our investments we’re making it fit for the future. This sends out a strong signal to the regional economy.”

KHS also aims to make local commitments above and beyond this. The enterprise is helping to devise a Science 2.0 master plan that the Dortmund council adopted in November of last year. In the field of production technology KHS is engaged in an exchange of expertise together with representatives from other companies and the TU Dortmund. “We’re pleased to be doing our bit for a strong regional economy and can apply our practical experience in this area. As a large industrial employer we also benefit from well-trained specialist workers,” Konrad concludes.
(KHS GmbH)

Newsgrafik #36156

'Successful open-heart surgery': Pyraser Landbrauerei invests in a KHS glass bottle filler  (Company news)

-Low Innofill Glass DRS consumption figures convincing
-Automated cleaning processes and format part changeovers
-Pyraser Landbrauerei boosts efficiency in production

Like the KHS Group, Pyraser Landbrauerei from the Franconia region of Germany looks back on a turbulent company history – one that began at practically the same time as KHS’. The success story of the Dortmund specialist for filling and packaging systems started in 1868. Just two years later Pyraser launched its first country beers to the local market. About 150 years on, the two traditional companies are now writing history together, with the Landbrauerei investing in an efficient, automated glass filler from KHS.

Photo: Pyraser Landbrauerei has gradually renewed its bottle cellar and in the process invested in a KHS Innofill Glass DRS glass bottle filler.

Seven days from ingress to production start was the clear instruction from Pyraser Landbrauerei – one that KHS followed to the letter. “It was successful open-heart surgery where nothing was allowed to go wrong,” smiles master brewer Helmut Sauerhammer. The brewery had gradually renewed its bottle cellar and in the process invested in a KHS Innofill Glass DRS glass bottle filler. Among other aspects, the decision-makers at the Franconian brewery were quickly convinced by the machinery’s consumption values and the low-oxygen filling process so essential when bottling beer. The patented KHS DRS-ZMS filling system uses just 210 grams of CO2 per hectoliter of beer. “We need a lot less carbon dioxide than the usual quantity common to the market to yield the same or even better residual oxygen values,” states Mike Herrmann, KHS Sales Germany and the man responsible for the project.

Another special feature at the country brewery is that Pyraser closes its beer bottles with aluminum caps. Because of this and the greater volume more oxygen would normally be pressed into the bottle compared to the amount required with classic crown corks; this would be detrimental to the beer as the product would then age more rapidly. To minimize oxygen pickup, the KHS glass filler therefore blasts the aluminum roll-on caps with CO2 in the capper. This joint development with the brewery means that the very good oxygen values in the bottle are the same as those for crown corks.

Efficiency boosted by automated CIP caps
Furthermore, the Innofill Glass DRS works with automatic CIP caps. “On the one hand, cleaning is considerably simplified as a lot less effort is needed for operation. On the other, the time saved as a result boosts efficiency in production,” Sauerhammer says. The number of manual interventions is reduced, as are toolless format changeovers thanks to hygienic QUICKLOCK fast-acting locks. The program is automatic and operated at the press of a button. Up until now employees had to place the CIP caps on the filling valves by hand. Cleaning processes can now be preset for specific times. They start automatically, with no manual intervention necessary. Any potential contamination of the filler, as could be the case where CIP caps are applied manually, is also prevented.

Water consumption significantly reduced
The new investment is also convincing with regard to sustainability. With its separate cooling circuit the ECO vacuum pump significantly reduces water consumption, meaning that Pyraser Landbrauerei uses only 80 liters an hour instead of the previous 800.

With the Innofill Glass DRS breweries profit from cutting-edge technology from the high-performance range and from a clearly structured machine design which considerably facilitates both operation and the entire production process. Pyraser Landbrauerei fills up to 26,000 bottles of beer or a maximum of 24,000 bottles of soft drinks per hour – with no hitches whatsoever since commissioning, Sauerhammer claims. “I’ve never known the first filled product to be ready for sale as quickly as here. We’re delighted!"
(KHS GmbH)

Newsgrafik #36102

Digital twin: KHS lowers fault-related costs with virtual machine commissioning  (Company news)

-Digital twin creates fully detailed virtual system image
-Virtual system commissioning to be increased
-Lead times reduced and fault-related costs lowered

In the future the digital twin will become a key component of industrial production. KHS already uses models to virtually map the machine and conveyor system commissioning process.

Photo: With the digital twin the mechanical components, electrical equipment and software programming must be able to access the exact same data.

With the help of smart, digital technologies KHS is networking and automating production processes step by step so that machines, products and complete lines can efficiently communicate and work with one another. “In particular what's known as the digital twin enables procedures to be transferred to a virtual environment by tracking and imaging all phases in a machine’s life cycle. All production processes and products can then be simulated virtually,” says Stefan Diesner, head of the Palletizing Product Center. Alternative, optimized production processes are displayed on the computer.

One of the major prerequisites for this is that engineering is consistent throughout the entire value chain in order to prevent what is known as data discontinuity at the interfaces between the various engineering disciplines, namely mechanical components, electrical equipment and software. Unlike the way a lot of work is done today, projects are not processed sequentially, i.e. separately and consecutively. Instead, in an ideal scenario all departments work in parallel across their respective disciplines on the implementation of a project and share a common data model – the basis for the digital twin that depicts every last detail of a system virtually and permits precise simulation.

The shared data challenge
For an engineering company like KHS, which not only manufactures a huge number of different machines but whose research and development departments also have a colossal geographical spread, this is a major challenge. The KHS engineers at the Palletizing Product Center in Worms have been working on the virtual depiction and simulation of machines and system parts for 13 years now. Simulation or virtual commissioning especially lend themselves to use with logistics systems such as palletizers or conveyors.

“Our aim is to continue to shorten lead times and lower fault-related costs by expanding our virtual commissioning setup,” explains Diesner. In order to estimate just how high these savings can be, it helps to take a look at the rule of ten. This states that the cost of fault correction increases by a factor of ten the later in the process an error is discovered. If a fault is only found and eliminated during factory commissioning, for example, the financial burden is ten times higher than if the correction had already been made to the software engineering during virtual commissioning.

Reduced time and effort
A further objective of the current project is to reduce the amount of time and effort required for virtual commissioning. One basic condition here is that the data is consistent. “With virtual commissioning we have control over data consistency,” Diesner explains. “All data is generated and stored at our production site, albeit still in a number of different systems. Further steps must be taken here before efficient and bidirectional access to this data is provided by a virtual engineering tool that includes simulation. Once this has been done, we can configure the system according to customer specifications or quickly and efficiently commission adapted machine designs on screen.”

In the meantime Worms is looking ahead: virtual commissioning is the first step towards digitalized systems for the beverage industry and the real digital twin. This will be able to do much more in the future, To this end, the digital twin has to be plied with more information, however, such as data on conversions for KHS customers or operational data from production – a challenging undertaking indeed.
(KHS GmbH)

Newsgrafik #36100

KHS promotes closed plastics loop with sustainable systems and solutions  (Company news)

The debate on plastic is presenting the beverage and food industries with a number of big challenges. The KHS Group is clear that the increased use of recycled PET provides a significant partial solution to this problem. The Dortmund systems supplier is thus focusing on sustainable products and services which help to close the recycling loop.

Photo: Every aspect of the Beyond Juice container concept from KHS has been optimized to ensure the best possible recyclability.

According to business magazine Forbes, around 140 PET bottles per head are circulated in Europe each year, with this figure more than twice that in the USA at 290. Despite all the criticism the plastic container is actually growing in popularity, with the number used increasing globally by around 4% per annum. Awareness of the need to recycle is also on the rise, however; according to Forbes, an estimated 57% of all used PET bottles were collected worldwide in 2019. For 2029 the magazine forecasts that this rate will increase to 68% – albeit with major differences from region to region. While 57% of all bottles could be collected in Europe, in the USA this would only amount to 30%. China, on the other hand, could become something of a model student and in ten years achieve an impressive collection rate of 82%. Collecting does not necessarily mean recycling, however: in the USA 70% of all collected plastics end up at waste disposal sites – and in Europe 30%.

Practically made for recycling: plastic
Yet plastic can be very easily recycled, especially PET. It is the only plastic that, when recycled, satisfies the legal requirements governing food grade materials. Whereas with other materials, such as polypropylene, polyethylene and polystyrene, the loss of quality which occurs on application of the usual recycling methods is irreversible, recycled PET can always be brought up to the standard of new material.

It is thus no surprise to learn that of the approximately 477,000 metric tons of PET used each year to make bottles in Germany alone, about 93% of this material is recovered and reused. Only roughly a third of this is used to make new bottles, however; the rest goes into the manufacturing of films and especially textile fibers. This means that the bottle-to-bottle recycling loop is deprived of a large percentage of this raw material.

There is also the development in price to be considered: while the cost of what is known as virgin PET is based on that of crude oil and benefits from the current low market price thereof, the charge for recycled PET has continuously risen over the last three years. Companies now have to pay about 20% more for rPET than for the original material – also because the supply cannot meet the growing demand.

High standards of quality
Not only do hurdles have to be overcome at the raw materials end; some beverage producers also have reservations. They often fear that the rPET material may discolor or that the level of intrinsic viscosity may drop. Another issue are safety standards and thus the harmlessness of the material. Time and again the question is raised as to whether multiple recycling can affect the quality. Although this has not yet been fully researched in practice, one thing is clear: as the polymer chains reform, no compromises must be made as regards the material quality as long as the additives can be completely separated off. The European PET Bottle Platform (EPBP) is just one of the institutions that helps to assure high standards of quality with its clear specifications and certifications. Whereas just a few years ago experimentation was rife and the beverage and food industries gained their experience with recycled PET through sheer trial and error, from a technical standpoint there is now nothing preventing the global use of high percentages of recycled PET. More and more beverage producers and brands are even opting to use bottles made of 100% recyclate. Where this is not yet the case, voluntary commitments are being publicized; Poland Spring, one of the biggest water brands in the USA, and Evian want to use recycled PET only by 2025. The other brands by Danone Waters, Pepsi and Coca-Cola plan to introduce a worldwide quota of 50% by this date. Their objective? They would like the consumer to interpret the slight graying that can occur when PET bottles are recycled several times over as a hallmark of quality for sustainable packaging.

Sound expertise: KHS specialists have been studying rPET since 2012
The KHS Group has also been examining the use of recyclate for some time now – in fact since 2012. KHS’ Bottles and Shapes™ service program focuses on the practical application thereof on the stretch blow molders and indeed all of the filling and packaging lines engineered by the Dortmund systems supplier. “We run tests to qualify recycled PET so that we can tell our customers in advance which impact the material will have on the blow molder and bottle quality,” says Arne Wiese, product manager for Bottles & Shapes™ at KHS Corpoplast. The aim to be able to quantify the various different qualities.

In doing so, KHS must work closely with preform manufacturers. They are ultimately often the companies which subject the washed PET flakes or rPET granulate to further thermomechanical processing and prepare them for injection molding. “We’re consulting with all of the major plastics processors in Europe on this topic,” Wiese emphasizes. And that is not all; KHS is also liaising with various engineering companies on preform manufacture. Thanks to this close cooperation, data from the injection molding process can be used just in time to adapt the stretch blow molding process. This makes bottle production faster and more efficient and improves the quality of the finished containers.

Adaptations needed: KHS has the right systems
“With recyclate the color can vary from batch to batch, for instance,” is how Wiese outlines one of the challenges faced. “Darker material absorbs heat better. The lower heating capacity requires less energy. This makes production more efficient yet means that adaptations must be made to the blow molding program on the stretch blow molder.” It is therefore essential that the effects are quantified, he continues. Another challenge is the intrinsic viscosity. “The longer the recyclate is boiled under vacuum, the longer the polymer chains become. This means that the intrinsic viscosity increases and the quality improves. However, this results in additional costs which not everyone is prepared to invest,” Wiese adds. “Here, we have to come up with ways of redistributing the material from uncritical areas – the bottle base in the case of still water – to more critical zones.” Experience shows that manufacturers of premium brands – whose containers have thicker walls – have less cause for adjustment than discounters, where all of the lightweighting options have often been exhausted. This is where recyclate can reach its limits.

In this context a technology developed by KHS in cooperation with inspection technology manufacturer Agr International scores points: Unit Mold Control, a digital, automated control system which regulates the blow stations on the InnoPET Blomax individually. It helps to control material distribution more precisely, reduces variations in the wall thickness by up to 30% and lessens any fluctuations in quality during stretch blow molding. “This is especially relevant when using recycled PET,” explains Frank Haesendonckx, head of Technology at KHS Corpoplast. “Here, the quality of the material can vary, meaning that the lower the preform weight, the greater the fluctuations in material in the bottle and the more unstable it becomes.” During continuous wall thickness inspection the new system identifies any unwanted material displacement and automatically counteracts this, states Haesendonckx. “Unit Mold Control combines weight reduction with bottle stability and is thus one of the many sustainable and effective answers KHS has to the challenges thrown up by the current packaging debate.”

According to Bottles & Shapes™ expert Arne Wiese there are no convincing arguments against the use of recycled PET in beverage bottles. The only relevant difference he sees between virgin PET and recycled material is the slightly darker color. This is a question of sorting, however – and only really visible in water bottles. With other beverages, such as the Beyond Juice bottle developed by KHS which is made entirely of recyclate, the consumer would not even notice the difference once the bottle is filled. As far as the mechanics are concerned, there is nothing to stop companies converting to rPET, providing ideal conditions for the creation of a functioning circular economy.
(KHS GmbH)

Newsgrafik #36008

From pharmaceutical niche product to established coating technology for the ...  (Company news)

...beverage industry

With its Plasmax coating technology and the FreshSafe PET® packaging system which has evolved from it, KHS offers the food and beverage industries a sustainable, environmentally-friendly system with the best possible product protection. Today’s coating system for PET bottles dates back to the 1990s when it was used in the pharmaceutical industry. How has this extraordinary story of success come about?

Photo: Bernd-Thomas Kempa (right), head of Plasmax Barrier Technology Global Account Management, and Dr. Joachim Konrad (left), former director of Plasmax Barrier Technology and now head of the Large Machine Product Division at KHS, are the trailblazers behind the development of Plasmax technology as a market-proven system for the beverage industry.

When Bernd-Thomas Kempa, who has been in charge of Sales & Service since 2012 and is now head of Plasmax Barrier Technology Global Account Management, and Dr. Joachim Konrad, who has been responsible for engineering as director of Plasmax Barrier Technology since 2014 and is now head of the Large Machine Product Division at KHS, talk about the history of FreshSafe PET®, frequent mention is made of the words “persistence”, “conviction” and “trust”. Together with their team, in a manner of speaking the two are the trailblazers behind the transformation of KHS Plasmax barrier coating technology from a niche product to a market-proven, tried-and-tested packaging system for the food and beverage industries.

The story of FreshSafe PET®, also known as Plasmax, began in the 2000s. This was when Schott AG and SIG Corpoplast launched a joint venture for the plasma coating of PET bottles to cater for changing packaging preferences in the industry. In doing so they pooled the expertise of an international manufacturer of glass and glass ceramics with that of a packaging producer and engineering company for the processing of plastics. Schott AG’s portfolio also included a glass coating which was applied to the insides of glass containers as a supplemental layer. “This protected highly sensitive pharmaceutical products from substance migration,” explains Kempa.

Challenges for customers and KHS
During the course of the joint venture a prototype of the first generation of Plasmax machines was developed and in 2002 the first Plasmax machine was tested in Switzerland with an output of 10,000 bottles per hour. Plasmax was also granted regulatory approval for use in the food industry in Europe, the USA and Japan. Two Plasmax 12D machines were then shipped to Japan for the protective packaging of sensitive, top-quality products. In 2006 Eckes-Granini was the first European fruit juice company to go to market using this technology. “The constant aim of development was and still is to integrate just one machine which satisfies bottling plant conditions and meets customer expectations,” says Kempa. System availability in particular had to be at an established level typical of the industry from the very start. “Looking at our success now and at the growing demand for this machine, we can say that it was worth it. We still nurture a certain start-up mentality in the team, though,” adds Konrad.

“With the dissolution of the joint venture and the takeover of Plasmax technology by KHS in 2008 we were given plenty of backing. However, as part of a global enterprise our small team was also required to prove that this technology could be just as sustainable in the beverage industry environment,” Kempa states. “Without the support of KHS and our parent company Salzgitter AG it wouldn’t have been possible to successfully transform this technology and break even. Success would have been equally lacking had we not had the special way of working together we still foster, with plenty of team spirit and great willingness shown by all members of the team,” he adds.

This support and sense of trust also increased among the company’s customers: alongside other machine sales in 2010 the prototype of the larger second generation of Plasmax coating machines went to Eckes with a capacity of up to 27,500 1.0-liter bottles an hour. In 2014 the company procured the world’s first FreshSafe block for its plant in Fallingbostel, a system blocked with a KHS stretch blow molder which produces a maximum of 32,000 0.75-liter bottles every 60 minutes. “KHS enjoys a trusting partnership with Eckes-Granini which goes back several decades where systems can be implemented to the benefit of both parties. This enabled Eckes to recognize the potential offered by a more sophisticated style of PET packaging very early on, for example, giving them optimum protection for their sensitive beverages,” says Kempa.

Plasmax portfolio continuously expanded
“Eckes-Granini saw the opportunities rather than the possible snags and was open to new developments and processes. We mustn’t forget that to start with this was new territory for all involved,” Konrad explains. Both parties profited from what was learned during the intensive partnership, helping to optimize innovative processes with regard to practical use and come up with totally new solutions. In this way Plasmax has steadily expanded its range of products over the years. The machine manufacturer now supplies not just its standard coating machine and the InnoPET FreshSafe block but also a Plasmax 2Q/4Q for the low-performance range and an InnoPET FreshSafe TriBlock with a stretch blow molder and filler/capper combination which can produce up to 48,000 bottles an hour. “FreshSafe PET® combines perfect product protection with sustainable recyclability. At the same time costs can be cut by saving on PET material. This gives us unbeatable arguments for this style of food and beverage packaging,” smiles Kempa.

The company’s success corroborates this: the interest shown by the beverage industry in FreshSafe PET® and other KHS PET technologies is on the increase because they are sustainable, believes Konrad. In order to perfectly meet the growing demand from the market, in 2016 production capacities at the Hamburg production site were increased. One major global soft drinks producer, among other clients, is now relying on FreshSafe PET® for its bottling operations at its plants in Asia and North America. “Together with this beverage bottler we’ve managed to apply all of the advantages of our Plasmax system. We’ve been able to achieve this positive result because all of the main issues – from preform and bottle design to the customer’s production options – were integrated into our search for the optimum solution. This was the breakthrough for us in the beverage sector,” Konrad exclaims.

Key factor for environmental protection
Several factors play a role when a customer makes his or her decision to buy. With FreshSafe PET® no unwanted substances enter the product from the outside, for instance – and valuable ingredients such as vitamins cannot escape. Thanks to Plasmax barrier technology sensitive and carbonated beverages also keep up to ten times longer than in the conventional PET bottle. This is a key factor, especially for bottlers whose products have to travel long distances. Furthermore, the wafer-thin layer of glass reliably protects sensitive products against loss of freshness and quality, thus making a considerable contribution to the protection of the environment. “The more reliable the product protection, the lower the amount of food wasted,” says Konrad. This barrier technology is also suitable for coating PET bottles made of recyclate (rPET) and for biodegradable containers.

Kempa and Konrad believe that the key factor for environmental protection is not just weight reduction but also the full recyclability of FreshSafe PET®. By avoiding the use of different material components this coating technology enables the PET material to be collected by type and thus containers to be fully recycled. This has been confirmed by a number of independent international experts and trade associations such as the APR1 and EBPB2, among others. In the face of the growing demand across the globe for clean recycling systems this is a crucial aspect, claims Kempa. “Customers and the public are increasingly calling for environmentally-friendly packaging systems; a product is only successful when it solves a relevant problem. With FreshSafe PET® we’ve created an environmentally-friendly and cost-efficient system which combines sustainability with the best possible product protection.”

Less use of materials cuts costs
In addition to environmental aspects and the protection of the product economy is also important. By using KHS technology bottles weigh less than those which contain additives, in turn cutting down on the amount of material required and thus saving on costs. Moreover, bottlers can also switch to using less expensive standard PET preforms, again reducing the cost per bottle.

“All of these factors have helped FreshSafe PET® evolve from a mere vision to a popular and sustainable form of packaging,” enthuses Kempa. “And we’re convinced that the success of this product is set to continue for some time yet. We expect that in the future environmentally-friendly packaging will be inextricably linked to our responsibility to further reduce our carbon footprint. KHS is contributing by having less food go to waste as it’s packaged in an optimized type of container.”
(KHS GmbH)

Newsgrafik #35899

KHS revolutionizes packaging processes at the Badoit mineral water bottling plant  (Company news)

First-class natural mineral water and an exclusive bottle design are the trademarks of the Badoit spring. From the bottled water to the packaging the premium brand makes the highest demands of the quality of its products. KHS has supported the company, part of Danone, since 1986. With its new Innopack Kisters SP A-H shrink packer Badoit is again benefiting from the expertise of the Dortmund machine and systems manufacturer. The packaging machine produces shrink film processing quality as yet unrivaled on the market with practically crease-free and consistently stable results.

Photo: With its shrink packer Badoit can process films of a significantly reduced thickness. The machine also uses an optimum width of film per pack.

France is heralded as a paradise for gourmets. The land of haute cuisine is renowned the world over for its award-winning wines, outstanding cheeses and high-class natural mineral waters. One brand which has established itself as a leader among carbonated natural spring waters is Badoit. The bottler from Saint-Galmier in the Département de la Loire, southwest of Lyon, has been working closely with the country’s top restaurants for many years. In doing so Badoit has earned itself a reputation as a top brand of high-quality mineral water in the premium sector. “Our customers make the highest demands of our products – and not just regarding our water. The perfect quality of the packaging also plays a decisive role,” says Etienne Marie, plant manager at Badoit.

The premium market: packaging quality plays a key role
Not only on the home market is the design of primary and secondary packaging a marketing factor which determines the product’s success. “Beverage brands can clearly position themselves on the market through the nature of their presentation and design,” explains Christopher Stuhlmann, head of the Line Product Division at KHS.

This aspect is especially important for Badoit. “As a premium brand our products not only have to differ from those of the competition in quality but also in appearance. The exclusive standard of our water must also be reflected in the packaging,” states Marie. The mineral water plant has therefore opted for bottles with a long, elegant neck, a unique feature on the French market.

Badoit requires better packaging quality
While the unusual bottle shape is a blessing when it comes to brand recognition, it has proved quite a challenge for the shrink packers used by the water bottler – also for its KHS Kisters packaging machines, some of which have been in operation for over 30 years. “The long-necked bottle makes it extremely difficult to produce a packaging quality which is outstanding in all respects,” Marie says. “The multipacks often had creases in the film, the print was distorted or the packs weren’t stable enough to withstand the logistics.” In addition, the outmoded packaging machines were no longer state of the industrial art when it came to efficiency and sustainability and were increasingly limited in their technological capacity. “We were no longer able or prepared to accept these compromises in packaging quality and machine efficiency,” claims Marie.

Badoit received support from its parent company. Danone Waters launched a competition between its individual brands and their production plants who then turned to their respective suppliers. “Danone Waters wanted a packaging machine which, thanks to significant further developments in the shrink tunnel segment in particular, considerably improves the standard of the shrink film processing available to date,” emphasizes Stuhlmann. Here, it was especially important that the lettering and brand logo on the packs was neither distorted nor creased.

KHS beats the competition
Following intensive talks on the new specifications to be adhered to and the first promising tests KHS was ultimately awarded the contract for the project. “We have a close and trusting relationship with KHS. Its many years of expertise in the development of packaging systems and the strengths of its latest generation of machines had us convinced once again,” is how Marie describes the reason for choosing KHS.

The systems supplier now had to live up to these high expectations. Under the supervision of Christian Schilling, head of the shrink tunnel development group at KHS, the machine and systems manufacturer put together an experienced team of design engineering experts. They were in close contact with the engineers in Saint-Galmier. “Throughout the course of the entire project the teams worked together openly and absolutely professionally as partners – as usual,” Stuhlmann reports.

Intensive optimization process
The expert team’s first task was to develop new components for Badoit’s packaging machines. The packaging specialists in Kleve subjected all system parts to thorough testing. After several optimization loops the improved components were integrated into the latest generation of the KHS shrink packer. “We then performed a series of further tests to make sure that our new developments satisfy Badoit’s high demands,” says Stuhlmann. Finally, the system passed its factory acceptance test and was shipped to Saint-Galmier.

Here, the KHS team replaced the old KHS Kisters shrink packer from 1986 with the optimized packaging machine. Following successful initial commissioning in December 2017 the packaging experts then focused on optimizing the system and its processes under real production conditions. “At first we weren’t able to fully achieve the required packaging quality with the combination of shrink film and machine used,” admits Stuhlmann. The specialists therefore spent the following months working on the various machine components, further developing, constructing, installing and testing them time and again.

Significant development for the entire Danone Waters Group
One major further development on the new generation of machines was to distribute the hot air supply more accurately on both lanes. The optimum alignment of the hot air flow on both sides of the multipacks loosely wrapped in film also had top priority for KHS. “Both are crucial for crease-free pack quality as the optimum processing window for the partly inverse effects was extremely limited,” Stuhlmann explains. The Dortmund company solved this problem with the help of a number of further developments, one being the specially designed central tunnel nozzle which will also be available to other projects in the future. The special air nozzles with their optimized perforated nozzle plates also help to create crease-free packs.

Furthermore, the KHS Kisters shrink packer sets a new benchmark when it comes to efficiency and saving on resources. One plus is that it can now process films of a much lower thickness. The machine also uses an optimum width of film per pack thanks to film web control. Badoit and its operators in particular also benefit from fully automatic film web control which is not only easy to handle but also ensures consistently high packaging quality. “With this new technical feature we were able to achieve the goal set by the customer, namely of providing optimum packaging quality while using the lowest possible amount of material,” smiles Stuhlmann. The team of experts also managed to boost the packer’s performance. On the further developed shrink packer up to 37,000 bottles per hour can be formed into packs of six on two lanes at the existing line speed.

The final acceptance test at the beginning of 2019 was performed to the full satisfaction of all involved. "KHS has met our requirements in every respect. The packaging quality has considerably improved compared to what it was,” praises Marie. Creasing and distorted print are now no longer a problem for the premium brand. “Thanks to the improved quality we’ve been able to double the size of the lettering on the packaging,” Marie relates. “This is a great advantage as regards product presentation. Our brand is now more visible to our customers than ever before.” The management of Danone Waters is also convinced by the final result. The French parent company considers the project to be an excellence reference for the entire company group.
(KHS GmbH)

Newsgrafik #35895

Reliable and efficient: Asahi Soft Drinks in Japan relies on the InnoPET Blomax Series V ...  (Company news)

...stretch blow molder from KHS

-Series V machine successfully running in Rokko in Japan
-PET bottles for still water ‘Rokko No Mizu’ holding between 600 milliliters and two liters
-Focus on efficiency for sustainable production

Photo: The InnoPET Blomax is one of the most reliable and efficient machines of its kind. Thanks to its optional new heating concept the Series V consumes up to 40% less energy compared to its predecessor.

A strong partner for Asahi Soft Drinks: KHS equips the Japanese bottler with up-to-the-minute technology for its Rokko water brand. The company is particularly convinced by the high quality and sustainability of the InnoPET Blomax Series V stretch blow molder.

Everyone in Japan is familiar with the brands produced by Asahi Soft Drinks, such as ‘Wilkinson’. Outside the country, too, the enterprise is also a known entity as a shareholder in or even owner of famous beer brands such as Tsingtao (China), Pilsner Urquell (Czech Republic) or Grolsch (the Netherlands). Asahi beer is a premium product and now exported worldwide. Not so well known outside Japan – but no less important for the holding – is the local soft drinks and water market. In 2018 Asahi achieved a turnover of over 360 billion yen (around €2.96 billion) in this segment.

With over eight production sites Asahi Soft Drinks Co., Ltd. offers a wide selection of products from ciders and teas through milk beverages to still and carbonated mineral waters. The company bottles its ‘Rokko No Mizu’ water at the location of the same name which is not far from the cities of Kōbe and Osaka. Rokko was one of the very first mineral waters produced by what is now an international concern, always driven by the high requirements made of the quality of the product. Today, it is filled into PET bottles to also meet consumer demand for a simple, safe and sustainable container.

Asahi Soft Drinks trusts in stretch blow molding technology from KHS
When looking for the best-possible combination of bottles manufactured reliably and to a high quality the choice fell on the KHS InnoPET Blomax Series V stretch blow molder. Asahi Soft Drinks sums up why the company ultimately opted for this particular machine. “We clearly aspire to technological leadership which is why we focus on sustainability, efficiency and state-of-the-art technology.”

The KHS InnoPET Blomax Series V was exhibited at the BrauBeviale trade show in Nuremberg, Germany, in November 2018. Prior to the event Asahi constantly kept up to date with KHS’ new developments and was one of the first customers to decide to commission the new series. This was also the case in 2008 when a prototype of the InnoPET Blomax Series IV found its way to Japan. Twelve years later the new and meanwhile established Series V is now producing 600-milliliter to-go bottles and large two-liter receptacles of still Rokko mineral water. A total of around 200 million containers a year are manufactured on the KHS system.

Blomax Series V cuts energy consumption by up to 40%
“We’ve built up a trusting relationship with KHS over many years,” explains Asahi Soft Drinks. “At no time have we regretted investing in the new series.” Asahi can attest that its energy consumption has been demonstrably reduced by up to 40%. The systems supplier from Dortmund has made this possible by including a number of further developments in its next generation of Blomaxes.

The InnoPET Blomax stretch blow molder has always been one of the most reliable and efficient machines of its kind. The Series V saves up to 40% in energy compared to its predecessor through the implementation of a completely new heating concept. The near infrared (or NIR) heater centrally installed in the closed reflector tunnel forms the nucleus of this. In the heater the preforms pass the centrally arranged heating units to both the left and right. This means that every single NIR heater is used twice, so to speak.

In the Series V KHS has supplemented its patented AirbackPlus air recycling system for an up to 40% saving in compressed air with its new EcoDry air management system. This uses the residual air from the blowing and recycling process to replace a separate air drier in the base mold area and in the blow wheel, again yielding significant savings in energy.

Further joint projects planned
KHS also affirms that its customer is satisfied with its new machinery. “When a Japanese company like Asahi trusts in us thanks to the notable efficiency and reliability of our machines, then that’s a great honor indeed,” says Matthias Gernhuber, head of Area Sales and Product Management for Asia-Pacific at KHS Corpoplast GmbH. “For saving energy in the interest of the environment and the demand for product quality are of especial importance to the Japanese.”

Convinced by the system performance and in order to meet its own requirements and keep up with its rate of growth, Asahi recently announced that plans for a second stretch blow molder from the new series are already underway.
(KHS GmbH)

Newsgrafik #35674

KHS FormFill in final acceptance: technology combines stretch blow molding and filling unit  (Company news)

-Revolutionary technology ready for operation before end of 2019
-Efficiency and high savings generated by single unit
-KHS readies system for market in less than two years since initial concept

Following the presentation of the future-oriented FormFill concept in 2017 the first system had been undergoing final acceptance in time for this year’s BrauBeviale. The new KHS technology combines the forming and filling of plastic bottles in just one process step. Operators benefit from considerable energy savings and a smaller machine footprint.

KHS first presented its FormFill concept at drinktec in 2017. Back then the ambitious plan was to sufficiently mature the technology in a good two years, enabling the first customer to then profit from its particular benefits. “We’ve learned a lot from the initial concept to the production of the market-ready system,” says Frank Haesendonckx, head of Technology at KHS Corpoplast in Hamburg, Germany. “We’re proud that we’re right on schedule. FormFill is the next stage in development for container forming and filling.”

With its technology KHS combines two processes that were previously separate. On present machinery two individual function modules stretch blow mold the PET preform and then fill the resulting bottle in separate stages. With KHS FormFill bottlers can now form and at the same time fill containers made of PET or rPET on a single machine. The system therefore takes up 40% less space than the standard stretch blow molder/filler blocks common to date. The time saved by the form/fill wheel has even enabled parts of the capping process to be integrated at this point. This then results in the machine being able to prevent product loss during container conveying.

Flexible formats for a range of products
The current tried-and-tested system has been configured for still water. However, the technology is just as suitable for liquid soap and laundry detergent and a whole range of hot fill applications. The current container formats vary from bottles with a volume of 500 milliliters to those holding 1.5 liters. “For the market launch in the coming year we’re focusing on outputs of 12,000 to 24,000 bottles maximum per hour,” states Haesendonckx. KHS subsequently aims to also provide this technology for the medium and high performance ranges. “Here, we’re engaging in active discussion with our clients so that we can also satisfy specific customer requirements.”

Efficient and low on space
“Taking all of the savings into account, FormFill consumes up to 60% less energy compared to a current stretch blow molder/filler block,” Haesendonckx smiles. As in standard plastic container processing to date, the machine first heats the PET preforms. However, instead of compressed air a controlled volume flow of product forms the preforms into containers. This procedure has several advantages: as the inside skin of the containers cools faster than with the standard method through direct filling, FormFill produces containers of greater stiffness with the same wall thickness, thus permitting preform material to be saved. What is known as the ‘water hammer’ effect makes design details such as logos more prominent, attracting a great deal of attention at the point of sale even without the presence of bottle labels. In a traditional compressed air process a blow pressure of up to 40 bar would be required to produce the same quality of container.

Another particular advantage is that after capping the trapped gas escapes from the product, creating a slight positive pressure in the container. “This also increases stability which has a positive effect on lightweight bottles especially,” explains Haesendonckx. Maintenance costs are also cut by the use of fewer components and format parts.
(KHS GmbH)

Newsgrafik #35652

Increased IT security requirements: KHS provides customer-oriented HMI upgrades  (Company news)

-Systems safeguarded against malware attacks
-KHS enables long-term availability of spare parts
-KHS ReDiS remote maintenance option

Photo: KHS provides customer-oriented HMI upgrades. The Dortmund systems supplier thus enables a long-term supply of spare parts and meets increased IT security requirements.

Many older operator consoles (HMIs) have been discontinued by the manufacturers. As a result operators are anxious about the lack of available spare parts and the threat posed by security flaws in old systems. KHS solves this problem by offering HMI upgrades with increased customer benefits. The Dortmund systems supplier thus enables a long-term supply of spare parts and meets increased IT security requirements.

“We’re seeing a clear trend towards IT security in customer inquiries for HMI upgrades. Besides the availability of spare parts our customers also expect additional options which safeguard their lines and machines against the threat of malware,” says Matthias Jansen, head of the Technical Support Service Division. KHS offers suitable systems and solutions to meet these demands.

During an upgrade to the current 2.0 version of the KHS HMI, which includes a ReDiS remote maintenance option, the engineering company takes the customer’s individual initial situation into account so that he or she can also safely operate his or her plant machinery in the future.

Whitelisting for old and new HMI versions
In order to block any potential malware attacks, KHS has introduced a special whitelisting system for old and new versions of the HMI. For machines with a version 1.0 HMI KHS provides whitelisting as a way of safeguarding systems against threats by installing a software upgrade. KHS goes one step further with the hardware upgrade which includes a current operating system to improve performance. “One major benefit is that both whitelisting and the HMI hardware upgrade can be installed in just under two hours,” explains Jansen. Installation or replacement is thus possible during the course of regular maintenance. “With our systems and solutions we offer operators a high level of security and availability for their KHS lines and machines which have been running reliably for years,” Jansen concludes.
(KHS GmbH)

Newsgrafik #35615

Basic Line Monitoring from KHS: web-based app increases line efficiency   (Company news)

-Simplified monitoring and evaluation of the line efficiency
-Faster identification of reasons for loss in performance
-Simple, intuitive user interface

With Basic Line Monitoring KHS offers its customers a web application which supplies data to assess the efficiency of a production line. It is based on the modular Innoline MES production management system. The module’s intuitive and convenient user interface simplifies production monitoring. This boosts line efficiency and provides safe access to performance data also outside the customer’s own network.

Photo: The web application captures key process data, among other things, which allows conclusions to be drawn as to the product quality, and consumption meters are also logged, with the help of which the total cost of ownership (TCO) can be lowered.

Innoline MES is a software program which is tailored to meet the requirements of the beverage industry and provides greater transparency in line monitoring and order management. It also performs control functions on the line. The IT system includes six modules with various functions which can either operate as stand-alone units or be used in combination.

Key process data captured
KHS has developed its Basic Line Monitoring (BLM) app based on Innoline MES which has successfully established itself on the market. It is the first product to be placed on a new, web-based Innoline MES 2.0 platform – a further development which requires less configuration effort. BLM only focuses on the data points which are actually needed to assess line efficiency and detect any sources of loss. The system makes it easier for customers to quickly identify weak points or causes of any loss in performance. It captures key process data, among other things, which allows conclusions to be drawn as to the product quality, and consumption meters are also logged, with the help of which the total cost of ownership (TCO) can be lowered. Wolfgang Heßelmann, the product manager responsible for Innoline MES at KHS, considers BLM to be useful on two levels. “On the one hand, the line can be brought up to capacity more quickly if operators can quickly identify where the bottlenecks are and react promptly and accordingly. On the other, an immediate analysis can be made on all devices that support the display of the web client as to the impact a fault has on performance.”

A web-based user interface makes the app convenient to use and means that data is visible both on mobile devices and on the machine monitor. The product is also intuitive in its operation thanks to the clearly structured menu.

Security of plant engineering networks a major issue for KHS
In addition to its user friendliness BLM is also convincing when it comes to digital security. “Because the module is web based, you don’t have to install any software on the computer. All the customer needs is a link to a website; he or she can then control who has access to the data and who doesn’t,” Heßelmann explains. With this the system can also be viewed outside the line in coordination with the customer’s IT setup.

OT security, the safety of plant engineering networks, has been a major issue for KHS for some years now. The systems supplier continuously analyzes potential weak spots and implements technical and organizational security measures. “We have to work closely together with the customer to effectively counteract OT security risks,” says Meike Schulz from Line Engineering Product Support at KHS. “Our security measures help to minimize the risk of a cyberattack and provide production systems with suitable protection. They help support a holistic security concept.”
(KHS GmbH)

Newsgrafik #35613

KHS and Ferrum agree cooperation for can seamers   (Company news)

In November 2019 KHS GmbH and Ferrum AG are to start a can seaming cooperation. This will focus on beverages for the American market. The aim is to intensify their successful partnership of many years. By cooperating more closely the two companies wish to benefit from one another’s expertise, particularly in the fields of research and development as well as service.

For many years now KHS has offered its customers can seamers from Ferrum, one of the world’s leading manufacturer of seaming machines. In entering into a cooperation with the aforementioned the German systems supplier aims to broaden its expertise in this product area. “Both KHS and Ferrum are enterprises which have a long company history and vast expertise,” explains Martin Resch (photo), CFO at KHS. “With our shared knowledge we wish to further develop this product area and further optimize our systems and solutions while providing everything from a single source. This means that our customers also benefit from the partnership.”

With the cooperation the Dortmund engineering company and Ferrum plan to develop even more efficient can seamers and fillers which always satisfy operators’ growing demand for sustainability and efficiency. To this end the partners aim to pool their expertise in a joint company in the USA. The overriding aim is to develop a powerful and robust block which combines can filling and seaming. Furthermore, smart services are to be developed and launched to market for customers of KHS and Ferrum.
(KHS GmbH)

Newsgrafik #35609

Conversion instead of new investment: KHS boosts efficiency and economy in bottle washing  (Company news)

-Increased efficiency through use of fewer resources
-Machine adaptation a worthwhile alternative to a new investment
-Services for returnable KHS lines

Photo: By reducing the weight of the bottle pockets the ECO carrier conversion package improves the energy balance.

Thanks to their great reliability KHS machines are often in use for many decades. Even after a very long period of operation it is not always necessary to reinvest. In essence the technology on bottle washing machines, for instance, has not changed. For years now the systems supplier has thus provided a variety of conversion packages which bring older machines up to date. This not only gives bottlers benefits in economy and efficiency but also cuts down on the use of resources and therefore helps to protect the environment. German beverage manufacturer Aqua Römer is one such customer to profit from a machine makeover.

When it comes to bottle washers in particular, replacing them means investing a great amount of cost and effort. The vast dimensions of the machinery alone often require bottlers to make constructional changes to their production plant, with some even having to open up the roof. For several years now KHS has offered a range of conversion packages which provide an alternative to procuring a new machine. With these the systems supplier brings old bottle washing machines for glass and PET bottles into line with the technical and ecological state of the art – with comparably little effort. As opposed to the actual technology, what has changed over the years is the amount of water and energy a machine like this consumes – namely much less. Practically every old machine can be upgraded and modernized within the space of just a few days.

Conversions yield many benefits
With its capacity-dependent fresh water control option KHS installs a control valve to adjust the water supply, considerably reducing consumption at a lower machine capacity. Older equipment can also be fitted with KHS’ Liquid Efficiency Spraying System (LESS). This is an electricity-saving function for spray pumps which minimizes the spray pressure during downtimes. As a result the machine uses 80% less energy in standby mode. Optionally, a flexible spray pressure also enables light glass or PET bottles to be processed.

Converting the bottle washer to ECO carriers lowers the weight of the bottle pockets by 25%. This puts less mechanical load on the drive system. The refurbished machine’s lower heat absorption yields a better energy balance. Cleaning media is also saved. Using the ECO chain, a weight-optimized bottle pocket chain, and plastic bushings lengthens the service life by up to 25% while reducing the rolling friction and current consumption. KHS’ understanding of sustainability goes far beyond resource efficiency, however. “With our range of conversions we make sure that customers can operate their machines as efficiently and for as long as possible,” says Matthias Jansen, head of the Technical Support Service Division at KHS.

In the upgrade process KHS Service adapts the conversion to suit the individual requirements of the customer and finds practical solutions. Regular machine maintenance and an intact machine structure are the technical prerequisites needed for implementation of the aforementioned measures for improvement. These amount to a mere fraction of what a new investment would cost. “Within one to two weeks customers then have a machine standing in their production shop whose performance data is up to the minute,” smiles Jansen.

Aqua Römer relies on returnable PET system from KHS
Aqua Römer in Mainhardt in Southern Germany is just one customer to benefit from a KHS upgrade. The machine there has been providing reliable service for so long that even electrical components which were available for many years can in some cases now no longer be sourced as spare parts. “We thus decided to upgrade,” states Marc Böttler, head of Engineering at the Mainhardt plant. On a returnable PET bottle line from KHS the beverage producer processes up to 24,000 bottles per hour holding from 0.5 to 1.5 liters. During the conversion to servodrives for the drive system it seemed prudent to also implement various measures to improve energy and media consumption. KHS thus installed its LESS function, ECO carriers and capacity-dependent fresh water spray. Böttler is convinced by the result. “We can now circulate the bottles on the bottle washer and don’t have to run them back if there’s a disruption. The line’s generally running much better. I’m reckoning on being able to use it for at least 15 more years.” As Aqua Römer is committed to sustainable production, Böttler is also delighted with the machine’s savings in energy and media.
(KHS GmbH)

Newsgrafik #35591

KHS develops an intelligent filling valve in the DnSPro research project  (Company news)

KHS presents the future of filling: at BrauBeviale the machine and systems manufacturer is to introduce a new, self-learning filling valve.

- Filling system uses artificial intelligence to optimize production processes
- Self-learning valve suitable for all beverages and container types
- New development minimizes operation and maintenance effort

KHS presents the future of filling: at BrauBeviale the machine and systems manufacturer is to introduce a new, self-learning filling valve. The system optimizes the production process with the help of artificial intelligence and at the same time considerably reduces the time and effort required for operation and maintenance. The feasibility of this flexible valve has been verified by KHS in the DnSPro research project.

“To date, depending on the beverage and container around 20 different types of filling valve are used,” says Jochen Ohrem, expert of R&D Management at KHS in Bad Kreuznach, Germany. “The beverage industry is increasingly calling for versatile filling systems. Digitally networked line and machine systems are also in high demand.” KHS would like to significantly push these changes which is why the Dortmund systems provider has taken part in the DnSPro research project alongside six other partners. Their common goal is to develop a self-learning filling valve with which beverage producers can fill all liquids into all existing types of container. This would do away with the need for manual conversions and the effort required for operation and maintenance would be greatly reduced, says Ohrem.

Self-learning and digitally networked
“We developed cyber-physical systems for this purpose, with the help of which the valve can determine how to best fill a certain beverage into a certain container as quickly as possible,” Ohrem continues.

The filling process is analyzed with the assistance of a camera. This continuously monitors the inclusion of bubbles and foaming to prevent excessive foaming and thus product loss.

With the help of microcontrollers and the camera’s evaluation electronics, the filling valve is opened to varying degrees by a stepper motor depending on the fill level. “The focus was on ‘learning’ a number of skills: self-configuration, analysis, self-diagnosis and, ultimately, self-optimization,” explains Ohrem. The future objective behind all this is to increase flexibility and energy and resource efficiency in production through the application of an autodidactic system of artificial intelligence. For the first time at BrauBeviale KHS will be presenting the key data on this intelligent filling valve which fully satisfies all of the previously specified project requirements.

Ideas for the future of the beverage industry
“The development is now entering the next phase where we’ll be gathering further experience with this prototype,” Ohrem states.

He already has one idea for later use of the valve in practice. Instead of a filling computer centrally positioned on the machine that regulates the process of all valves, in the future this task is to be managed locally by miniaturized computers installed on each valve group. This would allow a simple sensor such as a pressure sensor to be inserted into each filling valve which documents and analyzes the pressure curve, resulting in a process which optimizes itself of its own accord. “As less effort is involved in installation, this should yield a number of cost and time benefits, for instance during commissioning,” concludes Ohrem.
(KHS GmbH)

Newsgrafik #35506

Beyond Juice: KHS presents the first recyclable juice bottle made of 100% rPET  (Company news)

-Bottle concept provides maximum product protection for sensitive beverages
-Bottle fully recyclable thanks to FreshSafe PET® technology
-Renowned environmental service provider issues quality seal with top marks

There is an increasing demand from consumers and the beverage industry alike for packaging which saves on resources. Companies who design a container nowadays must also take its entire life cycle into account. KHS is addressing precisely this issue with its new Beyond Juice concept. For the first time the Dortmund systems provider has now developed a fully recyclable juice bottle made of 100% recyclate whose FreshSafe PET® barrier system offers unique product and freshness protection. In combining its market-proven systems KHS is taking an interdisciplinary and holistic approach to the beverage industry’s striving towards greater sustainability.

“With Beyond Juice we’re providing concrete answers to the challenges of the beverage industry, taking the juice bottle as an example. Also in view of the current debate on plastics practical, environmentally-friendly systems are becoming more and more important," says Philipp Langhammer, product manager for barrier technology at KHS Corpoplast. What is needed is an integral and sustainable type of packaging suitable for the entire spectrum of sensitive beverages. “When developing the bottle we thus strictly adhered to our credo of environmental protection, recyclability and maximum product protection,” states Langhammer. The PET container was designed by the KHS experts from the holistic Bottles & ShapesTM consultancy program together with environmental service provider Interseroh from Cologne according to their latest design guidelines.

Environmental service provider issues recycling seal
Following a number of optimizations the Beyond Juice bottle was issued with the Made for Recycling seal by Interseroh – the first PET bottle to score a full 20 out of 20 points. “Thanks to the seal on the label, for the first time consumers can now allow the bottle’s truly excellent recycling properties to help influence their decision to buy when standing in front of the supermarket shelf,” says packaging engineer Julian Thielen from Interseroh. “In the medium term, for packaging the criterion of recyclability will additionally become just as important as the aspects of product protection, convenience and attractiveness – also on an international scale.”

Unique product protection
The Beyond Juice bottle satisfies all of these criteria – among other things with the help of FreshSafe PET®. “We were only able to give top marks when analyzing the bottle’s recyclability because KHS SiOx barrier technology was used,” Thielen explains. “Alternative composite materials utilized as a barrier also often color the recyclate and yield an inferior quality.” Beyond Juice does not apply these otherwise usual composite materials which are added to the bottle material to protect the product and make pure-grade recycling much more difficult or even impossible. This topic is quickly gaining in significance on an international scale, too. This is illustrated, for example, by the plastics strategy presented by the EU Commission at the start of 2018 which aspires to make all packaging waste in Europe recyclable by 2030.

FreshSafe PET® also ensures that sensitive, high-quality juices and spritzers, for instance, keep up to ten times longer than those filled into uncoated bottles. This is primarily thanks to the wafer-thin layer of glass applied to the inside of the bottle which prevents oxygen from penetrating the bottle and CO2 from escaping from it.

Trouble-free recycling of the entire bottle
The label area on the Beyond Juice container has been kept so small that sorting systems recognize it as a PET bottle. This makes sure that the container can be reintroduced to the recycling loop and is not simply used to make energy. It was also important to select the right kind of adhesive so that the label can be separated from the plastic in the recycling process and there is no unintentional soiling during the washing process.

The new KHS bottle concept has also been developed as a film-free pack for recycling purposes. Dots of adhesive which are strong and secure yet easy to remove hold the bottles together. With Nature MultiPackTM from KHS the film otherwise used to package the PET bottles as a six-pack, for example, is no longer required. This adhesive is also easily removed during recycling. “By doing away with the secondary film around the pack we’re helping to further reduce this type of packaging waste by up to 90%,” Langhammer claims.

As the Beyond Juice bottle consists of 100% rPET, it significantly helps to reduce the carbon footprint left by packaging throughout its entire life cycle. New studies by recognized trade associations confirm that PET bottles made of 100% recyclate have a much lower carbon footprint than containers made of what is known as virgin PET. Langhammer concludes that “at a production of 50 million bottles a year more than 1,500 metric tons of raw material in the form of new PET could be saved by our bottle.”
(KHS GmbH)

Newsgrafik #35389

Energy efficient, intelligent and gentle on resources: KHS to exhibit smart beverage filling systems  (Company news)

Smart systems which save energy and resources: from November 12 to 14, 2019, KHS is exhibiting intelligent beverage filling technologies at the BrauBeviale trade show in Nuremberg, Germany.

- New glass filler platform sets standards in efficiency
- Automated processes save on energy and resources
- Full service packages improve line performance

Smart systems which save energy and resources: from November 12 to 14, 2019, KHS is exhibiting intelligent beverage filling technologies at the BrauBeviale trade show in Nuremberg, Germany. One example of the above is the new high-performance KHS glass filler with a capacity of up to 80,000 bottles per hour. With it the German systems supplier is helping the beverage industry move towards more efficient, more sustainable and increasingly digitized beverage production.

In November the international beverage industry will again meet in Nuremberg. At this year’s trade show KHS’ main focus will be on process efficiency, digitization and saving resources. “The entire production process is becoming increasingly smarter. As a trusted and reliable partner to the beverage industry we’re applying our extensive experience and line expertise to cater for this development,” says Dr. Johannes T. Grobe, CSO of the Dortmund machine and systems manufacturer. “At BrauBeviale we’re thus presenting intelligent technologies which will map out the direction KHS will take both now and in the future.”

Considerable savings in energy and resources
One example of this is the new generation of glass bottle fillers KHS will be showing to the public for the first time at the exhibition. With it the turnkey supplier is consistently advancing its aim of continuously reducing the amount of energy and resources consumed within the beverage industry. Among other features the filler has a unique ECO system and special evacuation and CO2 purging process for glass bottles. With this the system uses up to 50% less CO2 compared to conventional methods. KHS has also cut energy consumption by a maximum of 20% thanks to its optimized vacuum pump. “The protection of the environment is one of the determining issues of the moment. We thus offer our customers systems which specifically make their production lines sustainable and efficient,” explains Grobe.

Smart KHS systems noticeably optimize production processes
Here, an important role is played by smart engineering which noticeably simplifies, optimizes and automates production processes. To quote one example, a diagnostic assistance system monitors the entire filling process with regard to the evacuation and CO2 purging processes, for instance, to considerably minimize the amount of oxygen pickup. Broken bottles are also detected in all filling phases and the containers automatically channeled out of the system. “We’re constantly improving the efficiency of production processes. This in turn brings about a clear improvement in the line performance,” Grobe states.

Sustainable in every respect
In the future, too, one of KHS’ prime concerns is to significantly reduce our carbon footprint. Service plays a central role in the persistent pursuit of this goal. KHS enables its customers to operate systems for as long as possible and keep them in line with the latest technical, economic and ecological state of the art. Its bottle washing machine optimization program is exemplary in this respect. This aims to successively lower the amount of water and energy the bottle washers use.

In this context the Dortmund engineering company provides various smart service packages from the capacity-dependent fresh water controller to weight-optimized bottle pocket carriers. “We take a holistic view of our customers’ production and maintenance processes. With our extensive service program, including line optimization measures to boost efficiency and throughput, together we find the best possible solution and in doing so also help protect the environment,” declares Grobe.
(KHS GmbH)

Newsgrafik #35242

Trend-setting PET concepts: KHS focuses on circular economy at the K Show  (Company news)

-New PET bottle combines relevant sustainability aspects
-Practical line solutions contribute to environmental protection
-KHS looks toward positive business development

Photo: With its extensive PET portfolio KHS covers the entire value chain, ranging from innovative bottle design to energy and resource-efficient production processes.

KHS presents a new PET concept at the K Show based on the juice bottle as an example. It combines individual environmentally friendly packaging solutions in one container and thereby supports the theory of circular economy. The system provider shows how efficiency and sustainability go hand in hand by offering further line-compatible container solutions in addition to its Bottles & ShapesTM service offering. With these technologies, KHS provides its customers support in the conversion to an environmentally friendly and resource-conserving packaging portfolio.

The defining theme of the K Show in Düsseldorf in October will be how to combine process efficiency and sustainability. Kai Acker, CEO of KHS, emphasizes the continuously growing demand in the food and beverage industry for packaging solutions that support efficient production processes and at the same time contribute to the protection of the environment while maintaining a high level of product protection. "We already offer forward-looking concepts today. Our extensive PET portfolio covers the entire value chain, ranging from innovative bottle design to energy and resource-efficient production processes." As a system provider, KHS always has its finger on the pulse of the times with its topics, asserts Acker. "We provide support for conversion to environmentally friendly and resource-conserving types of packaging. Our portfolio offers concrete solutions for further promoting the concept of sustainability." With its innovative products and services Acker therefore sees KHS well positioned for the current financial year. "Against the backdrop of the company group's overall positive business development for KHS during the first half of this year, we are focusing on consistently developing our products, processes and solutions."

Trade show exhibit centers on the new bottle concept
With this in mind, a new PET bottle was developed, which will be presented for the first time at the K Show. The company combines various disciplines of its extensive know-how to create a unique container unparalleled to date. With this concept, KHS is consistently pursuing its strategy of reduction, recycling and reuse and for this purpose has concluded a partnership with an environmental service provider.

Compared to conventional PET containers, the system provider's new approach ensures a high level of product protection and a longer shelf life, in particular for sensitive beverages. Moreover, these bottles are completely recyclable and conserve on additional resources. "Our goal was to design a container with the smallest possible ecological footprint and we are consistently developing the circular economy approach further on this basis," says Acker.

Holistic line concept
The fact that system provider KHS at the same time designs the entire process chain efficiently and sustainably is also demonstrated by its line solutions for PET processing. These systems are not only able to effectively process recycled plastic, they are also hallmarked by energy and resource efficiency - from the stretch blow molder to palletizer.

With the Bottles & ShapesTM program, KHS is also furthering its developments along the entire production chain. Not only the initial ideas, drawings and 3D animations are developed for the desired bottle, but also prototypes, individual sample bottles and durable blow molds. Here again, reducing the use of materials and thus protecting the environment in cooperation with the customer is one of the company's central aims.

KHS will be exhibiting at the K Show in Düsseldorf from 16 to 23 October in Hall 13, Booth A75.
(KHS GmbH)

Newsgrafik #35272

KHS is driving the digital revolution in the beverage industry  (Company news)

Systems supplier researches networking and line optimization

Picture: KHS is currently actively involved in a good number of research projects which focus specifically on line optimization and digital networking

The entire sector is talking about digitization and Industry 4.0 – but what do these oft-cited terms actually mean for the beverage industry? One thing is clear: their potential is vast. Digital technologies simplify processes, intelligently network systems with one another and relieve operator workloads. At the same time the digital revolution presents beverage producers and engineering companies with many mighty challenges. As one of the leading systems suppliers KHS is well aware of the significance these complex change processes hold for the success of a business. The Dortmund machine and systems manufacturer is thus driving a number of research and development projects which specifically focus on digital networking and line optimization.

For KHS, one goal of its group strategy is to boost line efficiency and cut down on the amount of resources used such as materials and energy. “When deciding whether we implement an idea or not, it’s the added value for the customer that counts for us,” states Dr.-Ing. Matthias Schopp, head of Engineering Systems at KHS. The Dortmund systems provider thus finds it prudent to enter into close cooperative partnerships with its clients to this end. “These provide the perfect conditions in which to approach new technologies with realistic expectations and with an open mind as to their outcome,” says Schopp. “This is demonstrated by our various sponsorship projects, for instance, where we can experiment with new technologies in a kind of ‘protected space’. This can definitely be referred to as a platform which enables our developers, together with experts outside the company, to try out new ideas that carry a certain risk of implementation.”

Networking and cooperation with research institutes and universities
KHS believes one vital driver of progress to be networking and cooperation with external research institutes and universities. At the time of writing, for example, KHS is involved in a project for additive production in maintenance logistics managed by a research consortium comprising scientists from the TU Dortmund, Ruhr University in Bochum and Fraunhofer Institute for Material Flow and Logistics (IML). In this process, which is also described as 3D printing, components are produced layer by layer. Among other things, this form of manufacture permits complex component structures to be fabricated that cannot be made using conventional methods and are to simplify the production of machines in the future. The 3D printing process also speeds up the supply of spare parts as production is much faster than conventional manufacture. At the moment the selected projects focus on networking, digitization and process optimization, however. “The overriding aim of our research activities is to make our lines and machines even more energy efficient and gentler on resources so that our customers also profit from these projects in the future,” Schopp explains.

Faster filling processes thanks to self-optimizing systems
One research project KHS recently brought to a successful conclusion with its partners bears the name DnSPro. This acronym describes the development of a filling system that is equipped with various sensors and an intelligent logic controller. “The results from this project can form the basis for future filling machines where the machine can perfectly adjust itself to a new project automatically, with the automated variation of filling parameters replacing manual setup procedures,” is how Schopp describes the benefits of the self-optimizing filling system. This development centers on the application of machine learning for perfect adaptation to the bottle form, making the filling process quicker and more efficient.

The project has evolved from a cooperation between five industrial companies and the Ostwestfalen-Lippe University of Applied Sciences and Ruhr University in Bochum. “Both the cooperation and interdisciplinary development of the machinery were exemplary in this project and will make a major contribution to future product developments,” claims Schopp.

KHS line optimization makes major contribution to sustainability
When developing new products KHS attaches special importance to the subject of efficiency. Significant aspects here include saving on materials, media and energy and the optimization of lines and machines. KHS is constantly working to make its systems even more efficient. Each component, however small, is therefore seen as an important part of the whole. “New functions in individual assemblies are successively changing our systems and machinery. We’re constantly working on giving all components the maximum efficiency and perfectly coordinating them with one another,” Schopp claims.

KHS is also hoping to gain new impetus for this endeavor from the EnAP project. The goal here is to devise energy-saving concepts and line optimization processes that can be used in pneumatic and electrical handling systems. The project, funded by Germany’s Federal Ministry for Economic Affairs and Energy, not only intends to help save energy and resources but also to enable the beverage industry to keep its overall operating costs down to a minimum.

Digital technologies relieve operator workloads
Another primary future concern for KHS is the interaction between man and machine. “Our aim must be to make the operation of the increasingly complex technology demanded by growing market requirements easier for human operators. With the help of artificial intelligence we want to engineer self-learning and self-optimizing systems,” explains Schopp.

At the moment KHS is examining the main basic principles in this area under the umbrella of the CyProAssist project. The objective is to develop an assistance system for production which supports optimum human machine operation. “We want to help machine operators so that operating errors are avoided and error states corrected as quickly as possible to permit high line availability,” Schopp explains.

Badische Staatsbrauerei profits from digital KHS technology
KHS’ cooperation with Badische Staatsbrauerei Rothaus shows that the use of digital technology in the beverage industry is no longer a vision for the future but very much a present-day commodity. The systems engineer from Dortmund recently supplied its long-standing customer with an Innofill Glass DRS glass bottler which includes many additional digital functions, such as a camera-controlled high-pressure injection control system called OPTICAM. This produces a fine jet of water which displaces the residual oxygen from the filled bottle and is thus of great importance for the quality and shelf life of the beer. With this new development KHS allows the head of foam to be continuously monitored and regulated without the need for operator intervention. In this way Rothaus can not only reduce the beer loss due to excessive foaming but also detect and reject bottles with insufficient foaming.

The newly developed DIAS diagnostic assistance system also has a positive effect on the filling process. Sensors in every single filling valve ensure constant monitoring and visualization during filling. This means that any deviations from the target values are immediately recognized. A further special mention should be given to the fact that the evacuation and CO2 purging processes are monitored to ensure low oxygen pickup. Broken bottles are consistently detected and damaged bottles automatically rejected. The sensor data can be retrieved at any time and used to statistically evaluate results, with the help of which future possible sources of error can be detected and eradicated in advance. In practice this not only makes fast, targeted repairs possible and relieves operator workloads but also provides a basis for maintenance work.

KHS considers cooperation with partners in research and industry future proof
KHS has been developing pioneering lines and machines for more than 150 years and thus had a lasting impact on the beverage industry – as it still does. During this time cooperation with partners from industry and research has been and still is a major aspect of KHS’ key to success. Successfully concluded projects such as DnSPro, which give KHS and its customers real added value, are manifestations of the success of this intensive cooperation. “All told, we can observe that our current sponsored projects lie in the right fields of research and are yielding results that are directly tangible. Besides these, our projects are also having a positive influence on the expertise gleaned by our employees. After all, we all also learn as we work,” Schopp sums up.
(KHS GmbH)

Newsgrafik #35153

Innovative technology meets traditional craftsmanship: KHS’ Innofill Can C ...  (Company news)

... can filler has British craft brewer Magic Rock convinced

Since its launch in 2017 the KHS Innofill Can C can filler has successfully established itself on the market. Over 30 craft brewers worldwide are already benefitting from this new development from KHS.

- Wide range of products and beer styles
- High level of hygiene for craft beer
- Compact machine design for smaller breweries

Since its launch in 2017 the KHS Innofill Can C can filler has successfully established itself on the market. Over 30 craft brewers worldwide are already benefitting from this new development from KHS. The Innofill Can C is designed for low to medium outputs depending on the can size, enabling between 10,000 and 40,000 cans to be filled per hour.In addition to quick commissioning and maximum hygiene the system is convincing with its exceptionally low oxygen pickup and faster format changeovers. Magic Rock in West Yorkshire is just one example of the successful reception it has had to date.

In their search for great taste and exotic alternatives, for a number of years now British consumers have been distancing themselves from the traditional lager brands. Craftsmanship and premium products are finding increasing favor on the British beer market. This is backed up by a study carried out by Euromonitor International in 2019, for instance. It is also a development Magic Rock helped pioneer and is now profiting from. Thanks to the great demand for craft beer the brewery from Huddersfield in West Yorkshire recently extended its production facilities to include a KHS Innofill Can C can filler. With its 21 filling and three seaming stations the can filler has enabled the company to quadruple its previous output. “Crafted beers like the ones we produce have a good reputation and stand for quality. With the Innofill Can C we can guarantee the desired quality,” says Duncan Sime, manager of Retail, Media and Events at Magic Rock, explaining why the business procured its KHS machinery.

According to the Brits, their beers are characterized by their vibrant taste and attention to detail. In order to meet their own requirements, the brewery regularly modernizes its machines. Their investment in the KHS can filler, convincing with its modern technology packed into the smallest of spaces, is just one logical consequence of this. Magic Rock was able to integrate the system into its existing line without the need for any elaborate installation measures and commission it in the shortest possible time.

High demands made of hygiene and product quality
Making and filling beer is an art in itself – even more so for craft brewers like Magic Rock who make beers which are unpasteurized. During production the amount of oxygen pickup must be extremely low; at the same time the demands made of hygiene and product quality are very high. All of these criteria are fully met by the Innofill Can C. The bells on the filling valves are sealed without gaps by PTFE expansion joints. This does away with the need for the external water lubrication system usually required. The entire system is designed to ensure an extremely high standard of hygiene. At the same time cleaning is also considerably eased and optimum product quality obtained. For example, a super hoppy beer still tastes amazing many months after canning.

Wide range of products without flavor carryover
At the time of writing Magic Rock makes 15,000 hectoliters of beer per year and exports to 25 countries. “True to our motto of ‘same but different’ we offer our customers not only a distinctive core range but an ever-changing lineup of craft beers with an innovative, quality-driven approach,” Sime confirms. Whether IPA, pale ale or Surreal Stout, the brewery’s large assortment of beers is its unique selling point. This was also a reason why the brewers opted for the KHS can filler. The Innofill Can C is designed to allow flexible format setups and quick product changeovers. At the same time the computer-controlled, volumetric filling system ensures uniform fill levels and thus achieves a high filling accuracy when processing the 330- and 500-milliliter cans.

Economy plus sustainability
“With our compact can filler Magic Rock hasn’t just secured itself an economic advantage but an ecological one as well,” states Andy Carter, director of Sales UK & Ireland at KHS. Because of the patented purging process during filling this system has both extremely low oxygen pickup and low CO2 consumption. And last but not least, Carter adds, aluminum cans are one of the most widely recycled materials in Great Britain.
(KHS GmbH)

Newsgrafik #35139

Turnkey system for the water market: Armenian bottler grows with KHS technology   (Company news)

Armenia's biggest mineral water spring continues to grow. With the help of KHS the Jermuk Group CJSC has expanded its PET and glass bottle water bottling capacity and is now able to react more quickly to the growing demands of the domestic and international markets.

- Market leader Jermuk invests in glass and PET lines
- Modern labeling equipment for greater reliability
- New bottle design thanks to KHS Bottles & Shapes™

Armenia's biggest mineral water spring continues to grow. With the help of KHS the Jermuk Group CJSC has expanded its PET and glass bottle water bottling capacity and is now able to react more quickly to the growing demands of the domestic and international markets. The water of the same name has long been available in Europe, the USA and the Middle East. Due to poor labeling quality a special chapter has now been added to the success story that began many years ago.

Bottled water is becoming available to more and more people worldwide. This, in addition to increasing health awareness, is one of the main reasons for the move apparent on virtually all continents towards still and carbonated mineral water. This is a trend from which the Jermuk Group CJSC, Armenia's largest bottler, is also benefiting. With a population of three million inhabitants, this comparatively small market is an example of the development in many countries of Eastern Europe and Asia. With a share of up to 90% and more, bottling in PET bottles plays a major role on these markets. The remaining 10% is almost entirely distributed over the glass bottle segment.

Market leader in quantity and quality
As one of the most well-known brands in Armenia Jermuk feels responsible for bottling water. "It's not just a matter of growing as an enterprise," says Ashot Arsenyan, president of the Jermuk Group. "We also want to offer top-quality water, bottled under ideal conditions with the help of state-of-the-art technology." This is why he has been relying on KHS PET and glass bottle filling systems ever since construction of Jermuk’s new production facilities in 2010. Further expansion became necessary in 2017 to keep pace with the growing market. The Dortmund-based systems provider was once again able convince the customer of the merits of its plant engineering. In addition to filling and stretch blow molding technology Jermuk also purchased palletizing technology, CIP and blending systems and a shrink packer from KHS.

In addition the holistic Bottles & Shapes™ consulting program provided optimized bottle designs. However, problems developed in the wake of restructuring. While virtually the entire line was supplied by KHS, Jermuk had initially opted for another manufacturer to supply its labeling technology – and was not satisfied with the results.

Line from a single source
The labeling quality did not live up to the bottler's expectations of a premium product. Although the labels themselves and the bottles were flawless, damaged labels were a frequent occurrence. Together with KHS those responsible quickly realized that the third-party labeling technology was neither reliable nor precise enough for the paper labels being used. In accordance with their own determination to provide superior quality the people at Jermuk rectified their decision and commissioned a KHS Innoket Neo labeler on each of the two lines at the beginning of 2018. "The problem was solved as soon as the two labelers were put into operation. The quality of the packaging is now 100% compatible with our special product," says Arsenyan.

“The project in Jermuk is of particular interest to us as a systems provider because of its overall performance,” says Oliver Schneider, vice-president of the Eastern Europe sales region. “All components are perfectly matched to each other when we configure a complete line." Accordingly, the levels of availability and efficiency of the Jermuk system are high. At up to 25,000 bottles per hour for the glass line and a maximum of 20,000 for the PET line, for KHS the project is more in the low capacity range; the chances of further growth in Armenia are thus good.
(KHS GmbH)

Newsgrafik #35096

Flexible, compact and gentle on resources: KHS now also labels cans  (Company news)

-Systems supplier expands its labeling portfolio
-Compact machine with low energy consumption
-Flexible marketing options through self-adhesive labeling

Most decisions to buy are made directly at the point of sale: the significance of product presentation is growing, with an attractive visual appearance becoming ever more important. KHS is therefore now also offering its successful Innoket Neo labeling series (photo) for cans to manufacturers of small batches and producers with a high brand variety. The machine opens up new avenues in product marketing and flexibility in production. Warehouse capacities are reduced and energy is saved.

Images of production shops filled with pallets of differently printed empty cans will soon be a thing of the past. Says Cornelius Adolf, labeling product manager for KHS, “We’ve expanded our existing portfolio to include can labeling to give the customer more design options and enable these designs to be implemented faster with smaller warehouse capacities.” This is because minimum order quantities and long delivery times for empty cans limit flexibility. It is now possible to order unprinted cans within a much shorter period and to label them using the KHS Innoket Neo, thus simplifying logistics processes.

Wrap-around labels with optical alignment
The Innoket Neo can be used to apply self-adhesive film or paper labels. Here, the container can be either partly or fully wrapped with a label – including optical alignment. “The look and feel are unique”, is how Adolf explains the results of the self-adhesive labeling method. With this technology beverage producers can also respond much more rapidly and flexibly to the steadily growing variety of products and labels on the market. With this system the design or logo can be changed within a few hours and the cans dressed with suitable motifs. “Customers can even print their own labels. This considerably shortens the time to market. An attractive product is a clear distinguishing criterion at the point of sale," says Adolf. As no cans with varying motifs have to be ordered, costs are also cut as higher numbers of unprinted containers can be purchased.

The space-saving machine with its 14 can plates driven by servomotors comes from the established Innoket Neo module system and gives manufacturers of small batches and producers with a great variety of brands many benefits. At high machine availability up to 35,000 full or empty cans in all standard sizes can be labeled per hour. The machine can be positioned upstream or downstream of the filler. Format changeovers are quick and do not require any additional tools. The labeler also has a high level of energy efficiency, with a power consumption of just five kilowatts per hour.

Suitable can filler supplement
BrewDog, which claims to be the biggest independent brewery in Scotland, is already using the new labeling technology in combination with the KHS can filler already successfully established on the market. “Both machines supplement one another perfectly,” smiles Adolf. “We draw on decades of experience when developing systems for our customers and take heed of the changed demands and conditions governing the entire filling and packaging process.”
(KHS GmbH)

Newsgrafik #34963

The beverage industry and the protection of the environment: reduce and ...  (Company news)

... recycle are the order of the day

Picture: KHS now offers many different market-proven systems –particularly for PET containers and secondary packaging – which have been proved to specifically help its customers in their endeavor to be more sustainable.

KHS tackles the challenges posed by sustainable packaging and already offers market-proven systems to this end

The global debate on packaging waste, the associated use of resources and increasing regulatory pressure have further intensified the call of the beverage industry for new, alternative packaging systems. Concerns not only focus on saving on resources in the production process but chiefly on the packaging itself. PET containers and plastic packaging are currently very much in focus. One priority is to reduce and recycle the same. KHS supplies dedicated systems to meet these criteria and has at its disposal a wealth of expertise with which it strongly assists its customers in their striving towards greater sustainability.

KHS has been a partner to the beverage industry for 150 years and knows what it wants. In this sector the subject of sustainability has long been an issue. On the one hand there are climate goals to be met – or specifically a steady reduction of the carbon footprint in beverage production to be achieved through the development and use of systems which increasingly save on energy and resources. On the other ever greater importance is being attached to devising innovative packaging machinery which is of benefit to beverage producers and consumers alike. The way to produce ever more sustainable primary and secondary packaging involves two major lines of approach: recycle and reduce. In the first, packaging material is to be kept in constant circulation where possible by it being reclaimed, processed and continuously reused. In the second, many different ways are to be found of using less and less packaging material in order to save on resources and avoid waste. KHS pursues both of these objectives and offers specific technologies to this end.

FreshSafe PET®: the only fully recyclable barrier system
One big step towards engineering a strong, efficient and thus sustainable circular economy is to improve the recyclability of PET bottles to such an extent that they are suitable for bottle-to-bottle recycling. Fruit juice bottles in particular often comprise multilayer, blended or scavenger materials which are designed to protect sensitive beverages from external influences such as oxygen pickup. The aforementioned additives contained in the preforms often prove a hindrance to pure-grade recycling, however, and thus to their use in full bottle-to-bottle recycling. With FreshSafe PET® – a patented plasma coating system – KHS provides the only accredited fully recyclable barrier system to date which significantly increases recycling quotas for PET beverage packaging with enhanced product protection the world over. This has been confirmed by a number of recycling associations such as the EPBP1 and APR2. In the above process the inside of the PET container is coated with a wafer-thin protective layer of silicon oxide (SiOx) or chemically pure glass. This technology replaces the additives otherwise required. It guards sensitive products such as fruit juice and nectar against the penetration of oxygen and other substances and clearly reduces any additional loss of CO2 from carbonated beverages. The taste is retained, the beverages have a longer shelf life and full recyclability is made possible by this process.

Growing demand for rPET container systems
Another way of further improving the ecobalance is to increase the amount of recyclate or rPET used in PET containers – in some cases up to 100%. KHS provides the technology for this option. For example, in cooperation with bottler Mineralbrunnen Allgäuer Alpenwasser, preform manufacturer Plastipack and Berlin startup share the systems supplier has developed and successfully launched to market a 0.5-liter and 1.0-liter PET bottle made completely of recyclate. “Manufacturing a PET bottle from 100% recycled PET is possible – yet the devil lies in the detail. We have to approach this from a number of different angles,” says Arne Wiese, product manager for Bottles & ShapesTM at KHS Corpoplast in Hamburg, Germany. “Chemically recycled PET yields qualities which exactly match those of virgin PET. There are no restrictions here.” Yet much of the rPET used on the market is PET cleaned in vacuum conditions. “Here, qualities vary depending on the method of production,” explains Wiese. However, the quality of the rPET affects the bottle stability and weight. This means that the poorer the quality of the recyclate, the more stable the bottle has to be. This can be achieved by either increasing the weight of the bottle or optimizing the preform. “If a bottle is so light that it just about satisfies the requirement for stability, then any recyclate of an inferior quality means that this specification is no longer met,” Wiese states. Furthermore, at present rPET is not available in the required quality and quantity. Germany may boast the largest percentage of recyclate used in bottle-to-bottle recycling (32.6%), yet the remainder of over 65% is primarily used in the film or textiles industry. In addition, suitable pure-grade recycling systems are also largely lacking the world over.

Full concept Bottles & Shapes™
The impact the use of recyclate in different quantities and qualities has on the stability and weight of the bottle is taken on board, however, in order to positively influence the ecobalance. On the basis of various design criteria and material properties the holistic Bottles & ShapesTM consultancy program offers line-compatible bottle systems and solutions which strike the right balance between cost and sustainability issues, marketing criteria and user handling. “This calls for a wealth of expertise which we can provide with our decades of experience,” confirms Wiese. Moreover, KHS stretch blow molders have been optimized so that they can process preforms which contain up to 100% recyclate and, alternatively, biopolymer constituents3 – in other words, from renewable raw materials. “The relevance of these materials will increase considerably in the future. Here, we’ve provided the technical means of generating an increase in added value right down the line while saving on resources – such as with the new InnoPET Blomax Series V generation of stretch blow molders,” Wiese continues.

Secondary packaging with a high savings potential
The KHS Competence Center for secondary packaging systems in Kleve, Germany, has long been working on alternatives to classic shrink film. Many of these require extensive testing on the machinery. “The greatest challenge for us is the processability of the packaging materials,” says Karl-Heinz Klumpe, packaging product manager at KHS. “Shrink film made of recycled plastic demonstrates very different shrinking properties versus film made of new material. As an engineering company we can’t provide all the answers ourselves but instead have to coordinate closely with film manufacturers.” KHS stages workshops with these partners in order to do just that, where the participants aim to find out how the percentage of recyclate in film – as stipulated by the new German Packaging Law, for example – can be increased further. Changes to the chemicals or recipe of the film and adaptation of the machine equipment are among the necessary measures which need to be taken here. “The basic proviso is that there’s a standard of quality which is accepted by the big bottlers’ marketing departments. With film made of 100% recyclate the shrink results aren’t yet satisfactory. We’re continuing to rapidly drive development together here to close the gap between growing recycling requirements on the one hand and the demand for packs of ever increasing quality on the other,” Klumpe emphasizes.

Unique Nature MultiPackTM system
With the development of the Nature MultiPack™ KHS already has a film-free pack in its portfolio which is a pioneer when it comes to sustainability. This reduced form of secondary packaging even makes conventional shrink film on multipacks completely redundant. Here, PET bottles or cans are held together by nothing more than several strong dots of adhesive which are easy to remove. A self-adhesive carrying handle readies the pack for transportation. The dots of adhesive themselves do not impair the quality of the material to be recycled in any way whatsoever as they are easily removed during the recycling process. The Nature MultiPack™ was launched to market as a six pack of cans by the Carlsberg Group under the name of Snap Pack in 2018. Danone Waters first made successful use of this packaging system in 2016 when it launched its Prestige PET bottle for Evian. With it plastic waste is completely avoided as there is no more film packaging to be disposed of.

“The current debate on packaging waste has clearly further heightened our awareness for environmentally-friendly packaging systems,” says Klumpe. KHS now offers many different market-proven systems –particularly for PET containers and secondary packaging – which have been proved to specifically help its customers in their endeavor to be more sustainable. “We all take the public discussion seriously and are working directly with all those companies involved on further developments in an attempt to curb the pollution of our environment by plastic as much as we can with the help of our expert knowledge and expertise,” he adds. “In the end we’re all consumers and all of us bear clear responsibility for our own personal actions.”
(KHS GmbH)

Newsgrafik #34922

The beverage industry and the protection of the environment: reduce and ...  (Company news)

... recycle are the order of the day

KHS tackles the challenges posed by sustainable packaging and already offers market-proven systems to this end

Picture: share water bottle (source: share/Victor Strasse): In cooperation with bottler Mineralbrunnen Allgäuer Alpenwasser, preform manufacturer Plastipack and Berlin startup share KHS has developed and successfully launched to market a 0.5-liter and 1.0-liter PET bottle made completely of recyclate.

The global debate on packaging waste, the associated use of resources and increasing regulatory pressure have further intensified the call of the beverage industry for new, alternative packaging systems. Concerns not only focus on saving on resources in the production process but chiefly on the packaging itself. PET containers and plastic packaging are currently very much in focus. One priority is to reduce and recycle the same. KHS supplies dedicated systems to meet these criteria and has at its disposal a wealth of expertise with which it strongly assists its customers in their striving towards greater sustainability.

KHS has been a partner to the beverage industry for 150 years and knows what it wants. In this sector the subject of sustainability has long been an issue. On the one hand there are climate goals to be met – or specifically a steady reduction of the carbon footprint in beverage production to be achieved through the development and use of systems which increasingly save on energy and resources. On the other ever greater importance is being attached to devising innovative packaging machinery which is of benefit to beverage producers and consumers alike. The way to produce ever more sustainable primary and secondary packaging involves two major lines of approach: recycle and reduce. In the first, packaging material is to be kept in constant circulation where possible by it being reclaimed, processed and continuously reused. In the second, many different ways are to be found of using less and less packaging material in order to save on resources and avoid waste. KHS pursues both of these objectives and offers specific technologies to this end.

FreshSafe PET®: the only fully recyclable barrier system
One big step towards engineering a strong, efficient and thus sustainable circular economy is to improve the recyclability of PET bottles to such an extent that they are suitable for bottle-to-bottle recycling. Fruit juice bottles in particular often comprise multilayer, blended or scavenger materials which are designed to protect sensitive beverages from external influences such as oxygen pickup. The aforementioned additives contained in the preforms often prove a hindrance to pure-grade recycling, however, and thus to their use in full bottle-to-bottle recycling. With FreshSafe PET® – a patented plasma coating system – KHS provides the only accredited fully recyclable barrier system to date which significantly increases recycling quotas for PET beverage packaging with enhanced product protection the world over. This has been confirmed by a number of recycling associations such as the EPBP and APR . In the above process the inside of the PET container is coated with a wafer-thin protective layer of silicon oxide (SiOx) or chemically pure glass. This technology replaces the additives otherwise required. It guards sensitive products such as fruit juice and nectar against the penetration of oxygen and other substances and clearly reduces any additional loss of CO2 from carbonated beverages. The taste is retained, the beverages have a longer shelf life and full recyclability is made possible by this process.

Growing demand for rPET container systems
Another way of further improving the ecobalance is to increase the amount of recyclate or rPET used in PET containers – in some cases up to 100%. KHS provides the technology for this option. For example, in cooperation with bottler Mineralbrunnen Allgäuer Alpenwasser, preform manufacturer Plastipack and Berlin startup share the systems supplier has developed and successfully launched to market a 0.5-liter and 1.0-liter PET bottle made completely of recyclate. “Manufacturing a PET bottle from 100% recycled PET is possible – yet the devil lies in the detail. We have to approach this from a number of different angles,” says Arne Wiese, product manager for Bottles & ShapesTM at KHS Corpoplast in Hamburg, Germany. “Chemically recycled PET yields qualities which exactly match those of virgin PET. There are no restrictions here.” Yet much of the rPET used on the market is PET cleaned in vacuum conditions. “Here, qualities vary depending on the method of production,” explains Wiese. However, the quality of the rPET affects the bottle stability and weight. This means that the poorer the quality of the recyclate, the more stable the bottle has to be. This can be achieved by either increasing the weight of the bottle or optimizing the preform. “If a bottle is so light that it just about satisfies the requirement for stability, then any recyclate of an inferior quality means that this specification is no longer met,” Wiese states. Furthermore, at present rPET is not available in the required quality and quantity. Germany may boast the largest percentage of recyclate used in bottle-to-bottle recycling (32.6%), yet the remainder of over 65% is primarily used in the film or textiles industry. In addition, suitable pure-grade recycling systems are also largely lacking the world over.

Full concept Bottles & Shapes™
The impact the use of recyclate in different quantities and qualities has on the stability and weight of the bottle is taken on board, however, in order to positively influence the ecobalance. On the basis of various design criteria and material properties the holistic Bottles & ShapesTM consultancy program offers line-compatible bottle systems and solutions which strike the right balance between cost and sustainability issues, marketing criteria and user handling. “This calls for a wealth of expertise which we can provide with our decades of experience,” confirms Wiese. Moreover, KHS stretch blow molders have been optimized so that they can process preforms which contain up to 100% recyclate and, alternatively, biopolymer constituents – in other words, from renewable raw materials. “The relevance of these materials will increase considerably in the future. Here, we’ve provided the technical means of generating an increase in added value right down the line while saving on resources – such as with the new InnoPET Blomax Series V generation of stretch blow molders,” Wiese continues.

Secondary packaging with a high savings potential
The KHS Competence Center for secondary packaging systems in Kleve, Germany, has long been working on alternatives to classic shrink film. Many of these require extensive testing on the machinery. “The greatest challenge for us is the processability of the packaging materials,” says Karl-Heinz Klumpe, packaging product manager at KHS. “Shrink film made of recycled plastic demonstrates very different shrinking properties versus film made of new material. As an engineering company we can’t provide all the answers ourselves but instead have to coordinate closely with film manufacturers.” KHS stages workshops with these partners in order to do just that, where the participants aim to find out how the percentage of recyclate in film – as stipulated by the new German Packaging Law, for example – can be increased further. Changes to the chemicals or recipe of the film and adaptation of the machine equipment are among the necessary measures which need to be taken here. “The basic proviso is that there’s a standard of quality which is accepted by the big bottlers’ marketing departments. With film made of 100% recyclate the shrink results aren’t yet satisfactory. We’re continuing to rapidly drive development together here to close the gap between growing recycling requirements on the one hand and the demand for packs of ever increasing quality on the other,” Klumpe emphasizes.

Unique Nature MultiPackTM system
With the development of the Nature MultiPack™ KHS already has a film-free pack in its portfolio which is a pioneer when it comes to sustainability. This reduced form of secondary packaging even makes conventional shrink film on multipacks completely redundant. Here, PET bottles or cans are held together by nothing more than several strong dots of adhesive which are easy to remove. A self-adhesive carrying handle readies the pack for transportation. The dots of adhesive themselves do not impair the quality of the material to be recycled in any way whatsoever as they are easily removed during the recycling process. The Nature MultiPack™ was launched to market as a six pack of cans by the Carlsberg Group under the name of Snap Pack in 2018. Danone Waters first made successful use of this packaging system in 2016 when it launched its Prestige PET bottle for Evian. With it plastic waste is completely avoided as there is no more film packaging to be disposed of.

“The current debate on packaging waste has clearly further heightened our awareness for environmentally-friendly packaging systems,” says Klumpe. KHS now offers many different market-proven systems –particularly for PET containers and secondary packaging – which have been proved to specifically help its customers in their endeavor to be more sustainable. “We all take the public discussion seriously and are working directly with all those companies involved on further developments in an attempt to curb the pollution of our environment by plastic as much as we can with the help of our expert knowledge and expertise,” he adds. “In the end we’re all consumers and all of us bear clear responsibility for our own personal actions.”
(KHS GmbH)

Newsgrafik #34831

Digitization and ideas for the future at KHS - Technology for tomorrow  (Company news)

Picture: KHS is currently pushing ahead with numerous research projects, particularly in the fields of line optimization and digital networking

Industry pioneers such as Lorenz Adalbert Enzinger and Theo Seitz bear witness to the long tradition research and development enjoys at KHS. Like them today’s KHS engineers don’t always go with the flow but pursue many different paths in order to stay at the helm of progress.

For several years now a new acronym has been repeatedly bandied by economists and politicians: VUCA. It defines a world which is being increasingly characterized by volatility, uncertainty, complexity and ambiguity. Rapid fluctuation and high risk create challenging conditions for strategic corporate management – and for further technological development in industry. This naturally also applies to mechanical Industry pioneers such as Lorenz Adalbert Enzinger and Theo Seitz bear witness to the long tradition research and development enjoys at KHS. Like them today’s KHS engineers don’t always go with the flow but pursue many different paths in order to stay at the helm of progress. engineering and to KHS in particular, as the beverage industry, to which the Dortmund company is one of the leading systems suppliers, is subject to extremely dynamic cycles of change.

In order to survive in this VUCA world and prepare for the future, a certain agility of thought and action is required. For KHS, for instance, this means focusing on the relevant issues in research and development. While a manufacturer presents its customers with something new on its own initiative in what’s known as a technology push, a market pull primarily denotes an action triggered by the sales market.

Focus on requirements
Within its company strategy KHS has decided to focus on the fast-changing requirements of beverage producers. At the moment considerable effort is being invested in aligning the portfolio more specifically to target markets with a strong potential, for example. More than ever before the company has its ear to the market and aims to exploit the proximity of its sales and service organization to its customers. In order to successfully learn with and from its customers, established, trusting business relations are called for which KHS enjoys with many partners worldwide. Only within these is it possible to brave new technologies with realistic expectations and without bias as to the results. This includes openly discussing both problems and progress in a kind of ‘protected environment’ in order to be successful together – but also that those involved recognize when it no longer makes any sense to continue with a project.

Joint development
The partnership with the French food group Danone is a good example of this type of cooperation. This has resulted in the film-free Nature MultiPack™, first presented as a concept at drinktec in 2013, was readied for serial production and then launched to market with the Evian mineral water brand. The same technological principle was adapted together with Carlsberg for the beverage can and launched to the british and norwegian market in 2018.

New projects have to satisfy two requirements: the concept of effectiveness dictates that the right things are done, that is that the correct emphases are placed so as to come as close as possible to the market and yield the greatest possible benefits for the customer. The second requirement of efficiency demands that things are done correctly, in other words that maximum productivity is assured in the product development process from the initial idea to the rollout. This doesn’t prove successful when innovation is merely treated from a technological point of view. Greater priority is to be given to customer benefits through even closer dovetailing of and constant coordination between the Design Engineering, Production and Sales departments. More intensive communication between customers, KHS Sales and KHS Technology is to ensure that specifications can be better recorded and more directly implemented in the various system solutions.

To KHS networking and cooperation with external partners are of great importance as major drivers of progress. Not only customers but also suppliers are included here – for example those who provide measurement technology, components or software – as well as research institutes and universities. Two of the research projects KHS is currently involved in are dedicated to the application of new manufacturing technologies. One disruptive approach is the 3D printing of parts which can barely be produced cost effectively in the classic manner or whose geometric shapes are far superior to the doubles produced conventionally, for instance.

Digital pioneer
KHS takes a clear stance on the hype surrounding digitization which is often quoted when talking about the future viability of the industry: beyond the buzzwords and a number of interesting trends the sole criterion for the implementation of ideas based on digital technologies is the added value for the customer. Incidentally, KHS has every right to be confident here as it is a pioneer in many fields – such as in 3D line design which the company has been practicing for over ten years.

In addition to its digital projects KHS is concentrating on two more future issues. One of them isn’t new: this is the total cost of ownership (TCO) factor, including all measures which enable the beverage industry to keep its overall operating costs down to the absolute minimum. It covers aspects such as lightweighting, i.e. reducing the weight of PET bottles, material, media and energy consumption, an increase in productivity and simpler operation.

Efficient configurations
The other topic for the future which KHS has been committed to for a long time now encompasses modularity and standardization. Here, the aim is to provide as much variety as possible externally while producing with the lowest possible variance in house. A limited number of modules with tried-andtested functions forms the basis for this, with which the maximum possible number of configurations can be efficiently made. A system such as this permits lower lead times in production and faster commissioning. This approach is already being adopted in the field of aseptics, for instance. The result is a configured system with a manageable risk and a very high quality – and this is a foundation customers can build on.
(KHS GmbH)

Newsgrafik #34840

FreshSafe PET® from KHS: Association of Plastic Recyclers recognizes recyclability achievement  (Company news)

Picture: FreshSafe PET®: a wafer-thin layer of glass on the inside wall of the PET bottle combines product protection with the option of full bottle-to-bottle recycling.

- Technology combines product protection with recyclability
- Better barrier properties than composite materials
- Growing demand for clean recycling systems for PET bottles

The public demand for more sustainability is growing stronger. As a result the industry is increasingly concentrating on the recyclability of PET bottles. However, this type of packaging often contains composite materials which considerably hinder simple, pure-grade recycling. KHS’ FreshSafe PET® technology offers the beverage and food industries a unique alternative. A wafer-thin protective layer of chemically pure glass on the inside wall of the PET container combines product protection with full bottle-to-bottle recycling. This has now been officially acknowledged by North America’s Association of Plastic Recyclers (APR): this recognizes PET bottles coated using Plasmax barrier technology as meeting or exceeding APR’s most stringent Critical Guidance criteria for recyclability.

“Plastics are being subjected to increasingly critical questioning. People want more sustainable solutions from the industry,” says Jon Elward, head of Plastic Packaging at KHS USA, Inc. “The demand for clean recycling systems in particular is steadily gaining in significance.” The gradual ousting of mixed material PET bottles which are hard to recycle is progressively opening up the market to packaging systems which are easy to recycle. In this context KHS’ FreshSafe PET© technology provides a suitable alternative and has now been classified as meeting APR’s [1] most stringent Critical Guidance criteria for recycling. The wafer-thin glass coating applied to the inside wall of the bottle is washed off during the recycling process, producing pure PET. “We’ve fully satisfied the strict specifications and critical demands of the recognition process,” states Elward. “This again proves that FreshSafe PET® is the only sustainable technology on the market and a reference for the recyclability of PET bottles without composite materials.” With it sensitive products such as juice, wine, sauce and liquid food are protected from oxidation and carbonated beverages from carbon dioxide loss. Furthermore, compared to standard composite materials the coating process provides a much better barrier quality and ensures much longer product shelf lives.

APR aims to improve recycling quality of PET bottles
“This technology considerably facilitates recycling and at the same time improves the barrier properties of PET bottles,” confirms Steve Alexander, executive director of the APR. Through its recognition program the organization aims to improve the recycling quality of plastic bottles. According to Elward, interest among bottlers is growing in the system which has already been tried and tested many times over on the market. “There is an increasing demand for sustainable packaging.” With the recognition issued by the APR bottlers and recyclers can be more confident the technology supports the American PET recycling market. “This is a significant step in further establishing this technology,” Elward believes.

The EPBP also gives FreshSafe PET® top marks. In its design guidelines the platform rates the materials used with regard to their recyclability using a traffic light system. The SiOx coating is described as being the only fully compatible barrier technology.

KHS calculates individual TCO
Beverage producers of course incur additional overheads when they invest in FreshSafe PET© yet these quickly pay off as the overall operating costs at the plant are reduced. When they use this system bottlers can switch to less expensive standard PET preforms, relieving them of the obligation to source preforms from a specific manufacturer. KHS offers plant operators an individual consideration of the total costs accrued when using its barrier coating technology. “Measured against the huge benefit of additional product protection and longer product shelf lives in particular, the costs per bottle are actually lower than when conventional composite materials are used,” smiles Elward.
(KHS GmbH)

Newsgrafik #34787

Dr. Johannes-Thomas Grobe new head of Sales and Service at KHS  (Company news)

- Post to be assumed on April 1, 2019
- Dr. Grobe joins Kai Acker and Martin Resch on the KHS Executive Management Board
- Joint impetus for more growth

Dr. Johannes-Thomas Grobe is to be the new head of Sales and Service at KHS GmbH. This has now been confirmed by the company’s supervisory board. The 53-year-old shall be moving from Dürr Systems AG, a machine and systems manufacturer for the automobile industry, to the Dortmund systems supplier. Dr. Grobe joins chairman Kai Acker and Martin Resch on the KHS Executive Management Board.

The restructuring of the KHS Executive Management Board is now complete. “We’re very pleased to have gained a proven expert and leader for our company in Dr. Grobe. He brings with him a wealth of industrial experience gleaned during his professional career,” says Acker, chairman of KHS’ Executive Management Board. Dr. Grobe has extensive knowledge as an executive manager of product and technological developments, innovative projects and production and manufacturing processes.
(KHS GmbH)

Newsgrafik #34777

Straight to the supermarket shelf without a hitch  (Company news)

Peterstaler is now filling newly developed glass bottles – thanks to a project successfully implemented by KHS

Picture: Bottle formats, From 0.25 to one liter: Peterstaler uses various bottle formats – and for many decades now has relied on KHS technology to fill them all. In 2015 the mineral water bottling plant procured a new glass line from the Dortmund systems supplier, among other things.

To date KHS has developed over 14,000 PET bottle and 7,000 preform designs under the auspices of its Bottles & Shapes™ program. The systems supplier has now expanded its holistic expert consultancy program for container design to include glass bottles and cans. Fast, reliable, inline format changeovers in particular are a major factor for bottlers. KHS assures just this when new products are launched, with Peterstaler Mineralquellen GmbH from Bad Peterstal-Griesbach in the Black Forest now also convinced of this fact. After investing in a new glass bottle line in 2015 the company recently decided to launch new glass bottles for its mineral water. The machine manufacturer from Dortmund was once again largely instrumental in the success of the project.

This particular project in the Black Forest was approached from a different angle; where KHS cooperates closely with its customers on the development of new PET bottles, in the glass container segment the design was already fixed. Here, Peterstaler had decided to deploy a new glass bottle developed by the Society of German Mineral Water Producers (Genossenschaft Deutscher Brunnen or GDB). “There’s a definite move back to glass, with the amount used on the increase in the mineral water industry especially,” says Wolfgang Sum, engineering manager at Peterstaler Mineralbrunnen. “Closer attention is again being paid to quality, value and the regional aspect. Because of the greater weight of transportation and the higher costs this incurs, bottling in glass only pays off for deliveries within a 200-kilometer radius of our plant.” This was another reason for expanding the company portfolio.

Customer wants and needs met
When launching the new bottle format the chief focus was on the wants and needs of the consumer. “There are an increasing number of single households, for example, and lots of people don’t want to have to drag heavy crates around anymore,” claims Sum. To reach out to this target group Peterstaler decided to fill its products into new containers known as GBD pool bottles , a one-liter bottle in crates of six for people living on their own. “This type of crate is practical and easy to carry and transport,” Sum affirms. The mineral water bottling plant also fills 0.5- and 0.7-liter bottles.

In 2015 Peterstaler invested in a new glass line from the Dortmund systems supplier. The desire for new bottle formats again involved the experts from KHS in the fall of 2017 who implemented the project within the context of its holistic Bottles & Shapes™ consultancy program. “In this case this meant adapting the finished bottle to the line and converting this so that the filled crates of water find their way to the supermarket shelf without a hitch,” explains Armin Wille, head of Service Sales at KHS.

Entire line adapted to process the new glass bottle
Making use of the new bottles meant that the entire line had to be readjusted – from the decrater and bottle conveying system through the filler to the labeler and crater. The first bottle was then filled in the spring of 2018. Besides adapting the hardware KHS also reprogrammed the software for the whole system so that conversions are now possible at the proverbial press of a button within a very short time indeed. “The operator now intervenes as little as possible and knows exactly what he or she has to do to ensure that the filling result is always the same in the end. We attached great importance to this,” Sum states. For example, at the moment the changeover time from the last 0.7-liter bottle to the first one-liter bottle leaving the labeler amounts to around 45 minutes.

Peterstaler was also convinced by the sustainability of the KHS line. “Our prime source of heat for the bottle washer is still fueled by oil. We’re saving up to 35% here, for instance, and need less fresh water, thus producing less wastewater. Our electricity consumption has also been cut by up to 55%. A lot’s been achieved,” he smiles.

Long partnership between Peterstaler and KHS
Alongside fast changeovers and low energy consumption service and maintenance also play a major role for Peterstaler. “So many things hinge on the people. When we signed the contract for the system back then, I said that we’re now entering into a new partnership,” says Sum. Peterstaler is also totally satisfied with this partnership, he stresses. “In the coming year I’ll have been with the company for 30 years. When I joined, machines from KHS were already in use. That just about says it all.” The mineral water bottler not only operates Dortmund plant engineering on its glass line but also to stretch blow mold its PET bottles – here again relying on the proven Bottles and Shapes™ program. “We designed our first PET bottle together in 2004,” Wille tells us. Over the years KHS has continued to develop these containers for Peterstaler. “Here, through lightweighting we’ve been able to make considerable savings in the amount of materials used by the customer and thus also in costs,” Wille emphasizes.

The installation of the line in 2015 and last year’s conversions were something of a challenge, however, according to KHS senior service engineer Roland Streng. “The production shop had the added attraction of being on the second floor. As when we installed the glass line, during conversion we also had to lift the heavy format parts in through the roof using a truck-mounted crane,” explains Streng, who goes on to casually remark: “We managed to squeeze an entire line into a telephone booth. At 600 square meters, the area isn’t very big. It was all very tight. But we did it!”
(KHS GmbH)

Newsgrafik #34622

Rothaus takes the next step in glass filling with KHS  (Company news)

- Innofill Glass DRS with numerous improvements
- Badische Staatsbrauerei Rothaus AG first customer for the new system
- Patented system monitors the filling process and ensures beer quality

Picture: 132 filling stations - The unique DIAS diagnostic assistance system carefully logs the filling process. Pressure sensors in every single filling valve monitor the pressure, time and step sequences without interruption
(Copyright: KHS Group)

Better on all counts: Rothaus recently opted for the KHS Innofill Glass DRS filler and is now benefitting from a number of important new features. This is because KHS has made a number of specific further developments to its glass filler. For the brewery this means reliable, high-performance beer bottling.

The name is not new. For many years now KHS has provided its customers with an established glass bottler in the Innofill Glass DRS which has been frequently adapted to include new features in order to satisfy user requirements. The version of the filler now up and running at Badische Staatsbrauerei Rothaus AG is quite special, however. The flexible inline machine with its 132 filling stations for up to 50,000 bottles per hour provides hygienic filling with low CO2 and product consumption. KHS has considerably improved no less than four areas of the machine, drawing on its 150 years of expertise in brewery machines.

Rothaus fills 0.5-liter and 0.33-liter bottles on its new investment. Fast format part changeovers ensure a high level of flexibility during production planning and line efficiency. To this end KHS provides its hygienic QUICKLOCK fast-acting locking system as the new standard. Bottle guide parts can be exchanged with a few manual adjustments and remain securely in place thanks to the positive fit between the mount and the format part. The conversion time for fillers with a crowner is thus cut by up to 33% to just 15 or 20 minutes. “Simple lever knobs not only release and lock parts; they’re also robust and can withstand broken glass or chemicals,” states Ludwig Clüsserath, head of Filling Technology Development at KHS.

Clever technology in a compact form
In order to prevent bottle breakages from the outset, the Innofill Glass DRS is also equipped with the SOFTSTOP system which is registered as patent pending. This compact, hygienic bottle flowgate is activated at full power. Here, a light barrier measures the distances of the containers as they are fed into the filler. A brake wedge then gently decelerates the bottle flow so that the filling process and foaming take place at a constantly high output. This ensures stable filling quality. No conversions to other formats are necessary and the new braking ramp means that there is no additional scuffing and less noise.

Unique selling point for more quality
During the subsequent filling process the unique DIAS diagnostic assistance system carefully logs the filling process. Pressure sensors in every single filling valve monitor the pressure, time and step sequences without interruption. In this way any deviations from the target values are immediately recognized. A further special mention should be given to the fact that the evacuation and CO2 purging processes are monitored to ensure low oxygen pickup. Broken bottles are consistently detected across the entire processing angle and a bottle burst routine triggered. The sensor data can be invoked as a pressure graph on the monitor. "This gives operators the chance to detect any faults as quickly as possible," states Clüsserath. In practice this not only makes fast, targeted repairs possible and relieves operator workloads but also provides a basis for preventive maintenance. This data enables results to be statistically evaluated, with the help of which future sources of error can be eradicated in advance. This in turn ensures consistent quality and the continuation of ongoing operation.

Another significant feature is the camera-controlled OPTICAM HPI control system. The foam generated by HPI displaces the residual oxygen from the bottle and is thus of great importance for the quality of the beer. As the foaming is dependent on various parameters in the filling process, however, with its new OPTICAM system KHS enables the head of foam to be constantly monitored and regulated irrespective of the machine operator. This means that Rothaus can not only prevent undue beer loss due to excessive foaming but also detect and reject bottles with insufficient foaming. If the beer error rate becomes too high, production is stopped and the operators can read off the cause of the fault from a clear analysis report.

With the inclusion of the SOFTSTOP, DIAS und OPTICAM options the entire KHS system at Rothaus safeguards the quality of the beer throughout the entire filling process with these mechanical and digital system solutions.
(KHS GmbH)

Newsgrafik #34550

KHS now expands Bottles & Shapes™ consulting program to include bottles and cans  (Company news)

Machinery and systems manufacturer KHS expands its container development services

-Comprehensive advice on the entire value chain
-Cost savings for customers by optimizing material usage
-Format conversions implemented within up to eight weeks

Photo: KHS has expanded its services as indicated by the new Bottles & Shapes™ logo.

Individual design that combines functionality and efficiency: The KHS Group is expanding its Bottles & Shapes™ program and is now also offering its holistic consulting expertise in container development and optimization for cans and glass bottles. Customers have already benefited to date from decades of know-how gained by the PET bottle specialists. System provider KHS supports customers at an early stage starting from the idea up to market maturity, thus ensuring planning reliability and a smooth process of synchronizing the new product with the existing line. KHS also continues to assume responsibility for sustainable actions: besides making optimal use of raw materials, additional energy-saving measures also reduce the consumption of resources for bottlers.

The design of the glass bottles and cans should be oriented to the product and target group, the containers should be easy to handle, cost-efficient, sustainable and as easy and reliable as possible to process on the line: the requirements in the development of containers are initially numerous and often vague. This is exactly where this service comes into play with the consulting expertise from KHS. "When a bottler approaches us with a request to develop a new or improve an existing container, we have the overall process in mind right from the start," says Armin Wille, head of Bottles & Shapes™ at KHS. As a system provider, KHS focuses on rapid and individually coordinated project planning and implementation.

"We do this by discussing ideas with our customers, giving advice on individual design and, at the same time, identifying the efficiency potential throughout the entire line. Even in this first step, the high requirements for aesthetics and uniqueness of the containers is taken into account and are optimally combined with technical functionality in the best possible way," says Wille. KHS relies on digital 3D animation to develop containers with Bottles & Shapes™. "This enables us to make an initial assessment of the bottle shape and then systematically optimize it."

Production of precisely fitting format parts
Together with global partners, the experts carry out detailed technical evaluations in advance and check whether the cans or glass bottles can be filled without difficulty on customer machines. The new format parts are then produced to exactly fit the existing lines. By quickly assembling the corresponding format parts and the corresponding customization conversions on the system, KHS ensures that new products can be launched smoothly. Bottling plants are thus able to profit from high production reliability.

"Our turnkey system offers comprehensive project management extending from receipt of the order to commissioning," explains Wille. After completion of the technical clarification, machinery and systems manufacturer KHS implements the format conversions for filling cans, glass and PET bottles in the line within a maximum period of only eight weeks. Through integrated planning with the help of Bottles & Shapes™, KHS makes it possible to seamlessly launch new products to the market and ensure a reliable time to market and at the same time focus on material and energy savings by developing lightweight cans and glass bottles. Bottlers profit from reduced costs once the production launch is successfully completed.
(KHS GmbH)

Newsgrafik #34537

KHS Innopro ECOSTAB: flexible, resource-saving beer stabilization  (Company news)

-The result of 150 years of experience in beer stabilization
-ECOSTAB series has advantages over conventional systems
-Compact machine saves water and concentrate

In 1878 Lorenz A. Enzinger, heralded by the trade as the “Einstein of beer”, registered the first filter machine with the Imperial Patent Office. His innovative filter technology has had a lasting impact on the brewing industry. As the successor company to L.A. Enzinger KHS looks back on 150 years of experience in the filtration and stabilization of beer. Today’s beer stabilization systems in the ECOSTAB machine series are state of the art.

Photo: The KHS Innopro ECOSTAB permits reliable beer stabilization using PVPP.

In view of the increase in the number of exports beer stabilization is now also an important factor for medium-sized breweries. This is the only way they can ensure a long product shelf life which is essential on long transportation distances. Nowadays beer is usually stabilized by reducing either the number of proteins or tannins in the product. If the brewer filters a sufficient quantity of one of these substances out of the beer, the hazing is delayed. Using stabilizing agent polyvinylpolypyrrolidone (PVPP) in particular has major benefits as it is regenerative and can thus be utilized several times.

Resource-saving production with ECOSTAB B
KHS is setting standards in regenerative beer stabilization with PVPP with its ECOSTAB B technology. The system is based on the tried-and-tested KHS ClearLine frame design. All of the relevant components, such as pumps, control cabinet and stabilizing columns, are on one rack, with only the PVPP storage vessel in a separate unit. The modular design permits a flexible layout, with the low total system weight suitable for platform installation.

The ECOSTAB B has an output of 75 to 240 hectoliters of beer per hour. Thanks to its modular design the performance or capacity can later be extended at any time. The machinery is also distinguished by its low cost of investment. Furthermore, compared to standard systems the ECOSTAB B consumes up to 70% less PVPP. The high flux of up to 45 hectoliters per square meter through the filter strainers results in a very small system volume which in turn yields further benefits as regards water and concentrate savings, reduced blending amounts and setup times. The technological values demanded by the market, such as an oxygen pickup of under 10 ppb and PVPP losses of below 0.5%, are easily achieved with the ECOSTAB B.

Blocked filter elements a thing of the past
During production the system doses the pre-defined, recipe-controlled quantity of PVPP proportionally into the beer flow. The PVPP is deposited on the inside of the filter elements; the beer flows through these, is stabilized and fed to the downstream machine. Following production the PVPP is extracted and fed to the storage vessel and the filter elements are cleaned by rotating spray heads. Blockages on the filter surfaces are therefore practically eliminated.

Like the ECOSTAB B the continuous ECOSTAB C variant is also based on the tried-and-tested KHS ClearLine frame design. Three stabilizing modules form the heart of the system, with two always in production and one in regeneration mode. With a capacity range of 150 to 600 hectoliters per hour in continuous stabilization operation the ECOSTAB C series meets all market requirements.

INFO: Why stabilizing the tannin in beer with PVPP is worthwhile
During regenerative stabilization with PVPP the beer is stabilized in a system installed downstream of the clarifying filtration apparatus. This construction prevents the PVPP from collecting in the precoat filter vessel as a further solid – as is the case in non-regenerative stabilization – for the vessel can only absorb a certain amount of solids. In the regenerative variant it is thus not necessary to temporarily halt filtration once this maximum has been reached.

As less filter media has to be disposed of, the cost of using regenerative PVPP is also much lower than for setups which apply non-regenerative PVPP. In addition, the service life of the diatomaceous earth filter is significantly lengthened, with a return on investment of well under two years not unusual.
(KHS GmbH)

Newsgrafik #34542

The next generation: KHS presents the InnoPET Blomax Series V  (Company news)

-KHS improves all areas of its successful stretch blow molder
-More sustainable and efficient system for PET bottles
-World premiere at BrauBeviale in Nuremberg, Germany

In the development of stretch blow molders KHS can look back on over 40 years of experience in PET processing. It is therefore not without good reason that the InnoPET Blomax stretch blow molder has been setting standards in the production of PET bottles since its conception. KHS is now offering its customers a new milestone with the Series V (photo). The Dortmund systems supplier celebrated the world premiere thereof at this year’s BrauBeviale in Nuremberg from November 13 to 15.

The InnoPET Blomax stretch blow molder is one of the most reliable and efficient machines of its kind. At the end of the year, for the first time the general public will be able to preview the fifth generation which thanks to numerous innovations constitutes the most sustainable and powerful InnoPET Blomax to date. “We’ve always listened closely to what our customers have to say and work this into the continuous improvement of our stretch blow molder. In this series the greatest technological advance came with the development of the machine’s new heating concept, however,” smiles Marco Böhnke, product manager for block and stretch blow molding technology at KHS. “With the new Series V generation of machines we want to define just what a stretch blow molder can do.”

With the InnoPET Blomax Series V users opt for sustainable and powerful technology. The machine produces up to 90,000 PET bottles an hour holding between around 0.2 and 3.0 liters. It manufactures lightweight or premium variants just as reliably as individual bottles and containers. Depending on requirements six to 36 blow stations are possible, each of which has a capacity of up to 2,500 bottles per hour. Thanks to the machine’s quick-change system format changeovers involve only a few manual adjustments performed in a very short time indeed, ensuring permanently high line availability. The new generation of stretch blow molders seamlessly ties in with the KHS Group’s blocked machine strategy and can be combined with a filler, labeler or Plasmax barrier technology or with several modules at once.

Innovative features for more sustainability
The Series V saves up to 40% in energy compared to its predecessor through the implementation of a completely new heating concept. The near infrared heater centrally installed in the closed reflector tunnel forms the nucleus of this. In the heater the preforms pass the centrally arranged heating units to both the left and right. This means that the preforms have a very small pitch of 18 millimeters instead of the previous approximately 37 millimeters. KHS has thus been able to reduce the number of heater boxes by up to 40% which not only results in such vast energy savings but also cuts down on the amount of radiation loss.

New cooling concept saves even more energy
In the new DuoCooling cooling concept an external cooler supplies two cooling circuits with different temperatures. One of these is for the base mold and the other for the stretch drives, outer mold shells and, if required, the control cabinet cooling unit. This efficient cooling system prevents condensation from forming on the outer mold shells, for example, and further reduces energy consumption by up to 15%.

In the Series V KHS has supplemented its patented AirbackPlus air recycling system for an up to 40% saving in compressed air with its new EcoDry air management system. This uses the residual air from the blowing and recycling process to replace a separate air drier in the base mold area and in the blow wheel. In combination with DuoCooling this means that the entire blow mold is free of condensation and corrosion even in unfavorable climatic conditions. This enables operators of the EcoDry system to save approximately €50,000 at 5,000 hours of production per annum. “We’re proud to again be setting new standards with the InnoPET Blomax Series V and to pass these benefits on to our customers, allowing them to enjoy even more efficient and sustainable production,” states Böhnke.
(KHS GmbH)

Newsgrafik #34536

Fully recyclable: glass-coated PET bottles resolve juice production challenge  (Company news)

-Classic non-returnable PET bottles with composite materials currently difficult to recycle
-FreshSafe PET® from KHS provides sustainable solution
-With it beverage producers contribute to effective recycling process

Photo: At the moment PET juice bottles with a scavenger barrier are difficult to recycle and should therefore not enter the recycling system together with other non-returnable PET bottles. Glass bottle coating from KHS provides a system for pure-grade recycling.

Priority for fully recyclable PET bottles: when the German Packaging Law comes into effect on January 1, 2019, the new legislation will set down binding rules to increase recycling quotas. The amendment will levy higher fees for packaging which is difficult to recycle. This includes non-returnable PET bottles with composite materials for juice and nectar, among other products. Juice and nectar producers are thus currently looking for solutions which will help them to avoid the ensuing increase in costs. Here, FreshSafe PET® technology from KHS presents a viable alternative as it combines product protection with bottle-to-bottle recyclability. In view of the European Strategy for Plastics and other national legislation in countries outside Germany, KHS’ unique barrier technology is also gaining in significance at an international level.

When the new Packaging Law supersedes the present Packaging Ordinance at the start of next year as the legal framework for the German market, it not only defines a new target quota of 70% for returnable systems. The new regulations also prescribe increased recycling quotas for all types of packaging – also for plastics. As of January 58.5% of all plastic waste is to be recycled, i.e. the separate materials recovered and reused. From 2022 onwards this figure is to rise to 63%. At the moment the amount of plastic recycled in Germany totals around 36%.

In this context the dual waste disposal systems responsible for the collection of recyclable materials, such as non-returnable juice and nectar PET bottles, will be obliged to significantly increase their recycling quotas in the future. The new law allows them to reduce costs for easily and effectively recyclable materials and to charge more for packaging which is difficult to reuse. In the future the participation fees calculated on this basis will be determined by a number of ecological criteria. The better a type of packaging can be segregated and recycled, the lower the fees for beverage producers and retailers.

Additives in PET bottles complicate recycling
In particular, this rule has an effect on all those beverages whose packaging materials cannot be easily recycled as they contain additives. Juice and nectar producers especially, who fill their products into PET bottles, are affected in some areas. Non-returnable PET bottles are essentially fully recyclable; however, most of today’s juice and nectar bottles do not consist solely of PET. In many cases they contain multilayer, blended or scavenger materials which protect the sensitive beverages from external influences such as oxygen pickup.

The composition of these PET bottles is such that it does not allow the materials to be collected by type and recycled together with PET bottles which fall under the one-way deposit system, thus hindering the establishment of a global recycling process. “One quarter of the clear rPET flakes from yellow recycling sacks contain scavengers which impair the quality with their yellowish color, for example," states Herbert Snell, managing director of the MultiPet GmbH recycling company. “Mixing PET bottles like these with other beverage bottles made of PET makes it more much more difficult to use these rPET flakes for bottle-to-bottle recycling.”

This is why at the moment they cannot be included in the German deposit system for one-way packaging, says Snell. According to a current study by packaging market research institute GVM, about 10% of all non-returnable PET bottles do not carry a deposit, meaning that in 2017 38,000 metric tons of PET material bypassed the deposit system. At present the majority of such containers is used to bottle juices and nectars. If producers in this beverage segment fail to optimize their packaging portfolio with a view to full recyclability, they also face the threat of higher additional fees for placing classic PET bottles with additives on the market.

FreshSafe PET® juice bottles 100% recyclable
Beverage producers can find one alternative in the FreshSafe PET® technology provided by KHS. After the PET bottle has been manufactured, an ultra-thin glass coating is applied to its inside wall. These coated PET bottles are 100% recyclable as the coating is washed off during the recycling process, producing pure, fully segregated PET.

This is also confirmed by packaging expert Benedikt Kauertz, head of Environmental Assessment of Packaging at the independent Institute for Energy and Environmental Research (ifeu) in Heidelberg, Germany. “Glass-coated PET bottles allow juice and nectar bottles to be included in the pure PET cycle and their materials to be recycled together with other used PET bottles for water and carbonated beverages, for instance. To this end, however, the deposit-assisted return system must be extended to include these specially optimized bottles.”

97.9% of non-returnable deposit PET bottles are now recycled in this manner; juice bottles are not included in this figure. The first premium juice producers have realized this and are now already using the new FreshSafe PET® technology worldwide. This can reduce the circulation of non-returnable PET bottles which are hard to recycle in the medium to long term, acknowledges Mario Dechent, director of Research and Development for the Eckes-Granini Group GmbH. “We directed our attention to the full recyclability of PET juice bottles very early on. With FreshSafe PET® coating technology we’ve been using a sustainable system to fill our beverages for over ten years now, one which also permits pure-grade bottle-to-bottle recycling and thus increases the availability of useful recycling materials.”

Barrier costs also pay off thanks to lower fees
Beverage producers naturally incur additional costs when they invest in barrier technology. However, as the overall operating costs are reduced, the procurement pays off relatively quickly. With it juice and nectar producers can switch to less expensive standard PET preforms, relieving them of the obligation to source preforms from a specific manufacturer. Furthermore, compared to standard composite materials FreshSafe PET® provides a much better barrier quality and ensures much longer shelf lives. As they are fully recyclable, in the future FreshSafe PET® bottles prove more favorable when it comes to the calculation of participation fees.

KHS offers beverage producers an individual consideration of the total costs accrued when using this barrier technology. “Measured against the huge benefit of additional product protection and longer product shelf lives in particular, the costs per bottle are actually lower,” says Philipp Langhammer, product manager for barrier technology at KHS Corpoplast. “In view of the possible extra costs for the circulation of PET bottles which are tricky to recycle levied by the new Packaging Law, beverage producers should make their packaging portfolio future proof now and thus help to introduce a sustainable packaging system.”

Possible full ban on plastics which are difficult to recycle
Non-returnable PET bottles for juice and nectar which are difficult to recycle not only face the threat of higher fees due to their unfavorable properties. In the long term a complete ban on packaging such as the above could also even come into effect. The European Strategy for Plastics presented by the European Commission at the beginning of 2018 envisages all plastics having to be recycled by 2030. Various national initiatives in other countries of Europe are also promoting the reduction in plastic waste. In France, for example, the only plastics in use by 2025 at the latest should be recyclable. Moreover, in Great Britain new plastic packaging is to consist of an average of 30% recycled PET. International beverage producers have also begun to set themselves targets for a much higher recycling quota as a voluntary obligation.

“By steadily ousting PET bottles for juice and nectar which are hard to recycle the market is increasingly opening up to recyclable packaging systems,” emphasizes Langhammer. The growing demand for FreshSafe PET® also illustrates that barrier technology has already hit a nerve among beverage producers. With it KHS provides a system which can significantly raise recycling quotas for PET beverage packaging the world over. “The move away from composite materials which are difficult to recycle has already begun,” states Langhammer. “With the help of our technology the opportunities for processing pure PET are fundamentally increased.”
(KHS GmbH)

Newsgrafik #34413

100% recyclate: KHS and startup share develop unique PET bottle  (Company news)

-Bottle designed using Bottles & Shapes™
-Systems provider supports concept of sustainability
-Products filled into PET bottles made of 100% recyclate

Berlin startup share is the first beverage producer in Germany to sell its water in PET bottles made of 100% recyclate. With its expertise from the Bottles & Shapes™ consultancy program the KHS group supported the company by helping to design and develop the bottle in a very short time indeed.

Photo: With its expertise from the Bottles & Shapes™ consultancy program the KHS group supported share in the design and development of the bottle. (Picture source: share / Victor Strasse)

The plans are ambitious: in 2019 share wants to fill water into about a million bottles a month made entirely of recycled PET and thus save over 200 metric tons of plastic waste a year, according to the company. For several weeks now the product has been on sale at Germany’s supermarket chain REWE and drug store dm and has caused quite a stir in the media. “It took a long time for the original idea to be implemented,” says Iris Braun, head of Product and Social Projects at share. “Finalizing the technology and obtaining certification are both lengthy processes. Your partners are thus crucial.” Besides the two aforementioned retailers share’s other partners are bottler Mineralbrunnen Allgäuer Alpenwasser and preform manufacturer Plastipack, which is also the world’s biggest converter. KHS Corpoplast was also largely instrumental in the implementation of the project.

Experience from over 4,000 realized bottle designs
The German engineering company supported the startup in several ways, including in the development of the recyclate bottle design, states Marc Eysel, who is responsible for sales in Northern Europe at KHS Corpoplast. “We implemented the development very quickly and worked on a suitable design together,” he says. Thanks to its holistic Bottles & Shapes™ consultancy program the systems supplier was able to contribute to the share project experience drawn from over 4,000 designed bottles. “KHS developed the bottle very quickly for us which was enormously helpful,” says Braun. Eysel states that there were no unusual hurdles or challenges to be overcome through the use of 100% recyclate. “Manufacture is actually simpler as the material’s darker color makes the preforms easier to heat than PET bottles made of virgin material.” Besides providing advice on the bottle design KHS also helps with production. share’s still and carbonated water is bottled at the Allgäuer Alpenwasser bottling plant in Oberstaufen using KHS technology. The bottles are blown on an InnoPET Blomax stretch blow molder, with no special adaptations to the system necessary, according to Eysel.

Following the market launch of the recyclate bottle, interest is now also growing among other beverage producers, emphasize Braun and Eysel. “A number of bottlers wishing to increase the amount of recycled PET they use have now contacted us,” claims Eysel. “The protection of the environment also plays an important role at KHS. We support this by providing resource-saving plant engineering and also by developing sustainable PET bottles.” share hopes that it has provided the right incentives for more sustainability, states Braun. “In the end it’s the consumer who decides.”
(KHS GmbH)

Newsgrafik #34298

150 years of KHS: from equipment trader from Dortmund to global turnkey supplier  (Company news)

150 years ago to the day, on October 1, 1868, Carl Kappert and Louis Holstein founded the Holstein & Kappert equipment trading company in Dortmund, Germany, thus laying the foundations for KHS.

- KHS predecessor Holstein & Kappert founded 150 years ago
- Rise to one of the beverage industry’s market leaders
- Most recent developments focus on even more sustainability

150 years ago to the day, on October 1, 1868, Carl Kappert and Louis Holstein founded the Holstein & Kappert equipment trading company in Dortmund, Germany, thus laying the foundations for KHS. It took decades, however, for the enterprise to become a worldwide manufacturer of turnkey systems – many years of expansion, fusions and, first and foremost, continuous development of products geared to the future. Today, the KHS Group is one of the market’s leading systems providers for the beverage, food and non-food industries. For years the company has increasingly focused on sustainability in the development of new plant engineering.

“150 years of entrepreneurship and ingenuity have lent KHS the image it enjoys today. They are a central theme throughout our history and form the foundations upon which we now stand,” explains Burkhard Becker, chairman of the KHS Executive Management Board. Rolf Staab, executive vice-president of Human Resources for the KHS Group, also traces the success of the Dortmund systems supplier back to its roots. “Without the creativity, passion and perseverance of many generations of engineers, business personnel and factory workers our company wouldn’t have the international standing it holds today. Without them we wouldn’t enjoy the recognition our customers now show us.”

Pioneers since the first hour
KHS’ rise to worldwide partner to the beverage industry was a continuous process. It all began with the foundation of the Holstein & Kappert company in 1868. The Dortmund equipment trader initially only sold technical apparatus for the beverage industry. At the beginning of the 20th century the company began producing its own machinery which washed bottles and filled and packaged beverages, among other things.

The Seitz-Werke and Enzinger also celebrated their first successes in the second half of the 19th century. With the help of their innovative filters they revolutionized the wine and beer industries.

The fusion between Holstein & Kappert and Seitz Enzinger Noll Maschinenbau AG (SEN) based in Bad Kreuznach and Worms in 1993 was the ultimate milestone in the company’s history. Under the umbrella of the Klöckner-Werke, majority shareholder of Holstein & Kappert since 1979, the two manufacturers merged to form KHS Maschinen- und Anlagenbau AG.

Manfred Rückstein, head of Corporate Communication at KHS from 1991 to 2012, looks back to the time after the merger, which was at first quite turbulent. “We had to make it clear to our customers, who for decades had been loyal to either the one or the other brand, that the products from Bad Kreuznach, Worms and Dortmund were now all on an even par. In order to achieve this goal, it was absolutely essential to start using uniform product names.”

Rise to global supplier of turnkey systems
The fusion and the bankruptcy of the Klöckner-Werke were big challenges for KHS at the beginning of the 1990s. The solution was to have the company grow through further investments and acquisitions to become a turnkey supplier to the beverage, food and non-food industries.

Another factor which proved successful was the group’s early global orientation. At the end of the 19th century KHS’ predecessor companies were already looking for sales opportunities well beyond the German border. In 1893, for example, Lorenz Enzinger presented his innovations at the World Fair in Chicago. In addition to its five plants in Germany KHS today operates production facilities in the USA, Mexico, Brazil, India and China. The company is also represented by an extensive sales and service network on all of the relevant markets worldwide. “The name KHS is now synonymous throughout the globe with powerful filling and packaging systems for the beverage industry,” explains Becker.

Shaping the future with sustainable products
For years the KHS Group has increasingly focused on sustainability in the development of new, future-proof plant engineering. “As one of the market leaders in filling and packaging we’re fully aware of our responsibility to the environment. The issue of sustainability thus plays an important role in the development of our innovative and cost-effective products,” Becker states. Saving on resources is especially important in this context. Companies large and small the world over rely on energy- and resource-saving machinery to fill and package their bottles, cans and kegs. The KHS Group works towards producing lighter and lighter containers in its Bottles & Shapes™ program, to name just one example here. At drinktec 2017, for instance, the company introduced the lightest 0.5-liter PET bottle in the world to date, weighing just 5 grams. KHS also premiered a marketable concept for the forming and filling of plastic bottles which involves just one process step.

Further landmarks pertinent to the topic of sustainability include the development of the Nature MultiPackTM, which bonds bottle and can packs together using dots of adhesive instead of shrink film, and the invention of Plasmax barrier technology, which applies a coating of glass to the inside of PET bottles. Another of the new avenues KHS is exploring together with its customers is the digitization of the production process from 3D line design to virtual commissioning. With these and a number of further innovations in the pipeline the company is looking to the future with much optimism.
(KHS GmbH)

Newsgrafik #34058

Salzgitter AG: Kai Acker appointed new KHS GmbH Executive Management Board Chairman  (Company news)

The KHS GmbH Supervisory Board has appointed Dipl.-Ing. Dipl.-Wirtsch.-Ing. Kai Acker (photo) as the new Executive Management Board Chairman, effective October 15, 2018. He will be responsible for the technology, development/production, and human resources areas.

Mr. Acker, born in 1968, is currently managing director at LEONI Special Cables GmbH, Friesoythe and director of the "Enterprise & Industrial Projects" segment. After training as a power electronics technician, he studied electrical engineering at RWTH Aachen University and completed MBA postgraduate courses at the Technical University of Munich (TUM).

With regard to this personnel decision, Prof. Dr.-Ing. Heinz Jörg Fuhrmann, Salzgitter AG Executive Board Chairman, stated, "We are pleased to have acquired in Mr. Acker a competent executive with a broad range of industrial experience for this demanding position. I am sure that Mr. Acker will have a decisive impact on the growth-oriented development of the KHS Group. I would like to take this opportunity to thank my executive board colleague Burkhard Becker for laying the foundation for promising structures and the associated improved profits as the interim KHS CEO."

As an internationally-operating manufacturer of filling and packaging systems for the beverage, food and non-food industry, KHS GmbH, a 100% subsidiary of the Salzgitter Group, plays a leading role in this sector. It is an essential member of the Salzgitter AG technology division.

Newsgrafik #34049

Successful Innofill Can C: KHS implements additional machine size with greater capacity  (Company news)

-Huge interest in the new can filler
-Compact design gives smaller breweries many benefits
-For up to 27,800 cans per hour

It gives operators the technological innovations of the big machines and is convincing with its compact design and quick installation: with the Innofill Can C can filler KHS GmbH satisfies the demand of smaller breweries on the international market. Since introducing the prototype at drinktec 2017 there has been increased interest in the new technology from the Dortmund systems supplier. This is one of the reasons why KHS is launching a further machine size with a greater capacity to market this year.

Photo: Serial number 001 in Vancouver: Canadian brewery Steamworks recently secured itself the very first Innofill Can C can filler. There is also a great deal of interest in the machine among other medium-sized breweries.

At the world premiere of the Innofill Can C at drinktec 2017 Canadian craft brewery Steamworks procured the very first machine with a serial number of 001. In commissioning the can filler in February 2018 the Dortmund systems provider laid the foundations for the future machine series. “The high order entry demonstrates that this machine concept is already proving convincing,” says Kevin Rathbun, project manager at KHS USA. The machine manufacturer has already sold a number of the new can fillers worldwide. KHS shipped the can filler in a single container to the customer in Vancouver where it was commissioned on site on a plug-and-produce basis without any need for complicated installation processes. As the 21 filling and three seaming stations, valve manifold, cladding and control cabinet on the Innofill Can C form an enclosed, ready-to-produce machine unit, all that had to be done during installation was to connect up the electricity cables, piping and conveyors.

Only 14 days from delivery to commissioning

Just 14 days lay between delivery and the commissioning of the prototype. According to Steamworks its new plant engineering fills approximately 15,000 cans an hour in its standard 355-milliliter can format. The craft brewery also uses cans holding 473 and 500 milliliters. “With its new development KHS has again made the technical innovations of its big machines available to the craft brewing segment,” says Rathbun.

Steamworks’ CEO Gershkovitch is very pleased with his new can filler. “I like the KHS approach to design. In my experience things with a logical array work best.” In addition to the compact layout and fast installation, Gershkovitch also appreciates the machine’s hygienic design. In particular, this includes a gapless bell guide with PTFE expansion joints (Teflon) and bells which are lifted and positioned fully electropneumatically to seal the cans – without any mechanical action from cams and rollers. This does away with the need for water lubrication, simplifies cleaning and promises a service life which is up to twice as long as before.

The Innofill Can C is designed for low to medium outputs depending on the can size. KHS is to initially implement a further machine size this year in order to increase the capacity for filling 330-milliliter cans from 15,600 to 27,800 cans per hour. “In addition to craft brewers, who continue to grow and grow, medium-sized breweries are also increasingly asking for further cost-efficient machines for the medium capacity range,” emphasizes Rathbun. According to specifications the can filler can also process carbonated soft drinks or CSDs. “The output is then slightly higher”, Rathbun states.
(KHS GmbH)

Newsgrafik #34004

Innopas SX from KHS gives bottlers greater flexibility in the pasteurization process  (Company news)

• Tunnel pasteurizer with a high degree of microbiological safety
• New functions retrofitted quickly and easily
• Optimized spare part management

A high degree of microbiological safety: with the Innopas SX KHS GmbH provides a tunnel pasteurizer which with its modular design meets the growing demands of the beverage industry with its increasingly complex range of products and shorter market shelf lives. The systems supplier from Dortmund has also optimized spare part management for this flexible machine.

The beverage market is facing increasing levels of dynamic competition, with new flavors in new packaging formats hitting supermarket shelves at ever shorter intervals. Flexibility is thus becoming more of an issue when it comes to filling. The necessary pasteurization of filled and sealed beverage containers for longer shelf lives is a decisive factor here. The completely modular KHS Innopas SX tunnel pasteurizer for cans and glass and PET bottles fully satisfies these demands.

Dynamic adaptation to line behavior
The basic functions of the Innopas SX are initially identical to the tried-and-tested tunnel pasteurizer systems provided by KHS. The dynamic pasteurization unit or PU control system reacts variably to changes in conditions. If, for example, a fault occurs during the pasteurization process, the process temperatures are kept under control in the hot zones of the tunnel pasteurizer to ensure both maximum product safety and flavor stability. New features on the KHS Innopas SX include extended functions in the dynamic PU control system which result in greater flexibility and yield savings in energy and media. Much of this is attributable to the optional speed regulation function. The individual zone temperatures are automatically raised or lowered depending on the conveyor speed. “This allows the pasteurizer to dynamically adjust to match the line behavior within a range of 50 to 105% of the nominal capacity for most processes without making any drastic changes to the pasteurization units and maximum product temperature,” states Knut Soltau, product manager for Bottle Washers and Pasteurizers at KHS. This prevents stops and the corresponding consumption of media and at the same time has a positive impact on the behavior of the entire line.

With dynamic PU control from KHS the process temperatures are regulated within the hot zones of the tunnel pasteurizer to enable maximum product safety and flavor stability. With a new program for PU control the customer can independently adapt the pasteurization unit setpoint for a specific container type. Here, the full functionality of the PU control unit is maintained. “In this way subsequent product changes or new products can be easily made or introduced at any time,” says Soltau. “Bottlers can thus react quickly to changes on the market and product trends.”

Improved design
KHS has also made several improvements regarding the design of its Innopas SX, with maximum emphasis placed on easy operation. The tunnel pasteurizer is clearly structured and offers optimum access which chiefly simplifies the maintenance and cleaning of the system. For this reason parts of the process engineering, such as the heat exchangers and media supply, have been relocated on the machine as modules in order to further improve servicing and machine safety.

Spare part management for the KHS Innopas SX has also been optimized. The number of components the customer is required to keep in stock has been reduced while the delivery times for spare and wear parts have been shortened. As functions can also be simply retrofitted as an option, this boosts flexibility for the customer and ensures the future viability of filling lines at a low operating cost.
(KHS GmbH)

Newsgrafik #33933

Belgium's Brouwerij Martens produces bottles for the soccer World Cup with ...  (Company news)

... Direct Print Powered by KHS™

Design individual bottles in batches of one or implement special marketing campaigns within a very short time indeed: Direct Print Powered by KHS™ offers beverage producers great flexibility of design, thus giving them the competitive edge. The Martens brewery in Belgium is now making good use of this innovative technology and together with a French supermarket chain is placing specially designed bottles on the shelves for the soccer World Cup.

To mark the big kick-off in Moscow Belgium’s Brouwerij Martens is offering its premium beer in 32 country-specific bottle designs on the French market. Various images of the participating nations have been printed straight onto the PET bottles using Direct Print Powered by KHS™.

Back in 2015 the Belgian brewery was the very first beverage producer to launch directly printed bottles to market produced with the prototype of the Direct Print Powered by KHS™ system. Martens is convinced by the direct digital printing process and will also rely on the innovative technology from NMP Systems and KHS in the future, say the Belgian brewers.

The successor Pilot 1.0 version of Direct Print Powered by KHS™, which includes many new features, is now being used on the Martens production line. Pilot 1.0 incorporates technological additions which permit an even better quality of print at high speeds and enable each individual bottle to be printed with different motifs within a very short space of time. The customer is able to decide whether the individual designs are printed onto the bottles consecutively or at random. An additionally developed printed image inspection system ensures the standard of quality at industrial performance level.

Batches of one with individual motifs
Regardless of whether one or one thousand different bottle designs are printed, individual motifs which are adapted for marketing campaigns or even at the customer’s specific request and produced in the shortest time are possible on the Direct Print machine, giving the beverage producer a clear competitive edge. The short time-to-market phase is particularly ideal for marketing offensives such as the current World Cup push.

The bottles produced using the digital printing process are also 100% recyclable. This was again confirmed last year by the European PET Bottle Platform (EPBP) renewing the certificate granted to the process. PET bottles processed by Direct Print Powered by KHS™ have no negative impact on the rPET and are thus officially approved for bottle-to-bottle PET recycling.
(KHS GmbH)

Newsgrafik #33833

Changes to the KHS Executive Management Board concerning the Sales and Service Division  (Company news)

KHS in Dortmund, Germany, international manufacturer of lines and machines for applications in the beverage filling and packaging industry with over 5,000 employees, belongs to the Salzgitter Group’s high-growth technology business unit. As part of its Strategy 2021 program Salzgitter AG plans to further expand its technology business unit.

In order to follow KHS’ own growth strategy while simultaneously strengthening its inner performance KHS is implementing its company-wide KHS Future action plan. As part of the KHS realignment process Prof. E.h. Dr.-Ing. Johann Grabenweger, responsible for Sales and Service, is leaving the company by mutual consent. The Supervisory Board would like to thank Prof. Grabenweger for his 13 years of successful work in Production, Research and Development and, most recently, Sales and Service which has grown by about a third in the last few years.

Until a final decision has been reached regarding the appointment of a successor, Management Board responsibility for the Sales and Service Division shall be assumed by chairman of the KHS Executive Management Board Burkhard Becker.
(KHS GmbH)

Newsgrafik #33745

The successful KHS Innopouch Bartelt® K series concept: flexible systems for pouch packaging  (Company news)

-Machine with full range of servo equipment
-Format changeovers in less than 15 minutes
-Optional blocking with KHS palletizers

Flexibility, precision, ease of operation and hygienic safety: with its Innopouch Bartelt® K series KHS presents a pouching machine with a full range of servo equipment. With an ever increasing variety of products to be processed this system offers the beverage and food market many advantages with its short setup times and high level of productivity. It can also be combined with the KHS Innopack Bartelt® CMC cartoner for a pouch packaging line from a single source.

Consumers appreciate their low weight and easy handling, producers above all their low cost, as less material is needed for production: the pouch is definitely up to the minute. To date its growth in popularity was most discernible in the USA, yet demand for the practical pack is now also on the increase in Europe and parts of Asia. The best examples are smoothies or candies which are hitting supermarket shelves in this type of packaging with increasing frequency.

KHS offers customers its Innopouch K series poucher in two versions: an FS (fill and seal) machine for pouch filling and an FFS (form, fill and seal) variant for pouch production and filling. “The production stage can be flexibly retrofitted from the FS to the FFS version at a later stage as the machine is modular,” says Thomas Brooker, senior product manager at KHS USA.

Large variety of pouches
The horizontal, cyclic packaging system makes 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. The Innopouch K-400 changes formats at the press of a button using linear servotechnology. “This takes less than 15 minutes,” explains Brooker. “We’ve simplified and automated the time-consuming simplex and duplex conversions common to mechanical machines.” 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 machine produces up to 150 pouches per minute in duplex operation measuring between 100 and 380 millimeters in height and 100 and 400 millimeters in width. The maximum weight is 2.5 kilograms. “We thus give our customers the best possible flexibility during production,” states Brooker. With the Innopouch K series not only can large pouches be produced, such as for pet food, but also small bags for salty snacks or dried fruit. “Especially pouches which can be reclosed with a zipper are becoming more and more popular with consumers,” Brooker informs us. “Anything can be packaged – from ground coffee to mini salami roals.”

The standard version of the machine has four filling stations connected in series which can be added to as required. The dosing systems are selected according to the product to be filled, with volumetric systems, such as auger fillers, table feeders and sliding gate fillers, and gravimetric systems like multihead weighers all possible.

Extremely hygienic design
One special area of focus on the K series is its hygienic design. Thanks to the open construction there are no mechanical components beneath the grippers which require elaborate cleaning. In the machine housing spacers are used in place of the usual rubber seals. The film dispenser is also fully enclosed. These benefits considerably shorten the cleaning process.

The concept of the pouching line can also be further developed in combination with the KHS Innopack Bartelt® CMC cartoner. “This enables turnkey pouching lines to be provided from a single source,” smiles Brooker. The machine, configured as a horizontal cartoning system with continuous operation, has a servodrive controller for increased operational reliability and faster format changeovers.

KHS not only provides on-site service for the Innopouch K series but also remote maintenance by specialized engineers.
(KHS GmbH)

Newsgrafik #33704

Flexible and low on space: KHS presents innovative block systems for the sensitive range  (Company news)

-Hygienic filling of sensitive beverages
-Modules for individual customization
-KHS’ new chunk dosing unit

Yoghurt is no longer spooned out of the pot but drunk. Breakfast is no longer just eaten at the kitchen table but also on the hoof. And it should all be as healthy and sustainable as possible. This is one of the reasons why the demand for smoothies, milk and dairy products is steadily growing. KHS now provides its linear aseptic fillers for the bottling of these sensitive products also as a space-saving block system (photo). The Dortmund systems supplier is also expanding its portfolio to include a new modular system for filling sensitive products on rotary machines. The systems can all be tailored to suit individual customer requirements and are convincing with their high level of flexibility and microbiological safety.

There is a noticeable trend towards foodstuffs which are healthy and sustainable – and for breakfast on the go. Genetically unmodified milk and functional dairy products in unbreakable plastic bottles are becoming ever more popular. With its Innosept Asbofill ABF KHS provides a tried-and-tested linear filling system for the hygienic filling of products such as these. A number of new developments are now making these systems even more powerful. The machine is designed to fill up to 12,000 bottles per hour – or a maximum of 24,000 bottles every sixty minutes on the Twin version – holding between 0.25 and 3.0 liters.

“The great strength of this filler lies in its flexibility,” says Thomas Niehr, head of Aseptic Filling Technology at KHS. “The machine consists of a number of different modules and can thus be perfectly adapted to customer specifications.” The modular system permits later retrofits or components to be exchanged which is practical when market requirements change. A new transfer module also enables the Innosept Asbofill ABF to be blocked with a standard stretch blow molder from KHS. Thanks to neck handling, which at the same time gives operators maximum freedom of design regarding the bottle shape, the dimensions of the hygienic or aseptic zone can be kept down to an absolute minimum.

Microbiological safety, little space required
Another advantage of the linear system is that it is particularly efficient where there are frequent format changeovers and smaller product batches. It also reliably sterilizes bottles and closures. “The filler can be combined with a screw capper, film/foil sealer, nitrogen application or the new chunk dosing unit as required,” Niehr informs us. The KHS dosing module provides bottlers with flexible product design options by adding chunks to the beverage, such as whole cherries, strawberries, vegetables or cereals with a length of up to ten millimeters.

New modular system for rotary machines
Besides the new developments for its linear filler KHS also offers a new modular system for its rotary machines for high-performance filling. The new concept can process between 24,000 and 36,000 and in the future even up to 54,000 bottles per hour depending on the bottler’s required production capacity. The system offers plenty of scope as regards the bottle size, with container volumes ranging from 250 milliliters to 1.5 liters. With the new KHS concept the machines can be adapted in the form of standardized modules for three hygiene categorization classes specified by the German Engineering Association or VDMA. Ultraclean KHS filling machines (UCF) satisfy the requirements of VDMA class III, extended shelf life fillers (ESL) those of class IV and KHS aseptic filling machines those stipulated by VDMA class V. “In the future a KHS filler can be configured depending on which hygiene class a beverage producer’s products fall under and precisely tailored to suit the individual specifications of the customer,” says Niehr.
(KHS GmbH)

Newsgrafik #33636

Preventive maintenance of aseptic machines: KHS offers fixed modules at fixed prices  (Company news)

The standards of quality in hygienic filling are high – as is the cost of production downtime.

-Unplanned downtimes avoided
-Longer machine service lives and greater production reliability
-Fixed prices for all maintenance modules

The standards of quality in hygienic filling are high – as is the cost of production downtime. It is thus important to carry out preventive maintenance on machines in order to detect any possible wear and microbiological risks in good time – and to avoid them. For high standards of quality and safety in the long term KHS provides a proven preventive maintenance system for both the linear and rotary version of its Innosept Asbofill aseptic filler – with fixed modules at fixed prices.

The established, optimized system is an important component in KHS’ holistic range of services, giving bottlers the safety and reliability they need in the production process. “In this way failure through wear is avoided, risks to product safety are detected well in advance and the availability of the system is ensured,” states Thomas Niehr, head of Aseptic Filling Technology for KHS in Bad Kreuznach, Germany. “Should just one single part of the machine fail, the financial and material loss can be vast if the bottler has a sterile product in the tank which has to be processed quickly, for instance.” For this reason KHS offers special maintenance modules which Niehr describes as being comparable to a service for a car. The intervals are always gauged by certain time cycles and machine operating hours, with KHS providing the material packages and engineers.

Overall machine state inspected
During maintenance not only are smaller wear parts replaced; the overall condition of the machine is inspected and settings are corrected where applicable. The customer is given detailed information on all results in a concluding machine status report. The Dortmund systems supplier provides fixed maintenance packages for all of its aseptic machines at a set price which varies depending on the required intensity of maintenance and fulfillment of certain service tasks by KHS. “If KHS takes on the entire management during servicing, this has many benefits for the customer. The replacement of wear parts can’t be avoided. Preventive maintenance, however, ensures smooth production as all processes and machine data are consistently read out and monitored by our engineers,” says Niehr. “We then coordinate the entire maintenance management process together with the customer. This again increases machine and production safety and reliability. A dairy, for instance, can’t afford long downtimes." The more regularly and intensively a system is monitored by KHS, the shorter any downtimes are. The practiced course of events executed between the bottler and KHS’ engineers also cuts down on the amount of administrative effort, thus further reducing costs, claims Niehr.

This generates a number of calculable advantages for the operator, as fixed costs also enable budgets to be securely planned, with identical installments paid at pre-specified intervals. Niehr emphasizes, “Customers know exactly how much maintenance costs them. It’s also possible to compute costs according to the number of bottles filled, with a fixed allocation of maintenance costs to product giving bottlers planning security.” As an option KHS also supplies additional spare part and emergency packages beside the replacement of wear parts within the scope of its maintenance modules.

“Preventative maintenance thus has many benefits,” smiles Niehr. By avoiding unplanned downtime the overall cost of production is lowered in the long term. Unlike an unscheduled system standstill, preventive maintenance can be sensibly integrated into the production plan. “It’s a prudent investment,” concludes Niehr, who also points out that KHS is constantly further developing its system of maintenance. “The aim is to fully equip the machines with sensors in the future so that they’re monitored online by the electronics. With this form of preventive maintenance the amount of downtime will be reduced even further and production will become even more efficient and cost effective.”
(KHS GmbH)

Newsgrafik #33587

KHS Innoket Roland 40: compact labeling machine for the beverage and food industries  (Company news)

With the Innoket Roland 40 the KHS Group has launched a compact labeler to market. The KHS Innoket Neo’s little brother has a capacity of 2,500 to 25,000 containers per hour and is thus specifically tailored to the requirements of the food industry.

-Space-saving table machine for the low capacity range
-High-quality mechanical design based on the Innoket Neo
-Many expansion options for individual requirements

Photo: The Innoket Roland 40 is the little brother of the Innoket Neo, suitable for outputs of between 2,500 and 25,000 containers per hour.

Dortmund, February 13, 2018 – With the Innoket Roland 40 the KHS Group has launched a compact labeler to market. The KHS Innoket Neo’s little brother has a capacity of 2,500 to 25,000 containers per hour and is thus specifically tailored to the requirements of the food industry. The Innoket Roland 40 can be fitted with various labeling stations and is characterized by its ease of use and the accustomed high quality offered by KHS.

“The machine is specially geared towards lines with a low output,” explains Cornelius Adolf, labeling product manager at KHS. During development particular attention was paid to simple operation and a high degree of economy. The table machine is not only of interest to craft breweries but also to companies in the food sector, such as manufacturers of canned food, sauces or dressings./p>

In its standard version the Innoket Roland 40 comes with two cold glue stations. This allows shoulder and neck labels to be applied at two levels by the first station, for instance, with the second station affixing back labels to the bottles. Alternatively, self-adhesive stations, a combination of cold glue and self-adhesive technology and hot melt labeling processes can be used.

Proven components from the high-capacity range
Inside the Innoket Roland 40 are countless quality-determining components taken from the established high-performance KHS Innoket Neo labeling machine. These include the carousel, infeed and discharge stars, folding doors, installation and format parts and guides and on the cold glue station the gripper cylinder and label magazine. The Innoket Neo servo feed screw has also been applied and integrated here, permitting gentle bottle stops.

Plenty of upwards scope
The KHS development also provides many different opportunities for extension to cater for individual labeling tasks. It is possible, for example, to equip the Innoket Roland 40 with the KHS VarioDrive electronic bottle plate control system. Other options include mechanical alignment by side notch in the infeed star and the fitting of traveling applicators, the latter used for cap or lid labels. U-shaped labels – as tamper-evident seals for twist-off caps, for instance – can also be labeled and rolled on. Optional sensors check for the presence of labels at certain points, for example in the label magazine or on the gluing roller, and for other factors such as broken bottles. With its many expansion options the KHS Innoket Roland 40 is thus perfectly suited to cater for all requirements in the low capacity range.

At Anuga FoodTec the Innoket Roland 40 demonstrates its perfect suitability for the food industry through its point of display alone. The technology can be viewed live not at the KHS booth but at Florin Gesellschaft für Lebensmitteltechnologie mbH at booth E20/F29 in hall 10.1 where the system designed for an output of 2,500 to 25,000 containers per hour will be exhibited.
(KHS GmbH)

Newsgrafik #33520

KHS presents new chunk dosing unit and compact systems at Anuga FoodTec  (Company news)

At Anuga FoodTec in Cologne, Germany, the KHS Group will have compact and flexible systems specially designed for the beverage, food and dairy industries on display.

-Compact systems for the food and dairy sector
-Individuality and modularity meet market demands
-Trend for PET systems still in focus

Photo: Innoket Roland 40 labeler

The new KHS chunk dosing unit for functional milk beverages permits gentle filling of chunks measuring up to 10 x 10 x 10 millimeters. The systems supplier from Dortmund will also be highlighting its further new innovations for sensitive beverages. KHS will be exhibiting its systems at booth A60/A68 in hall 8.1 at Anuga FoodTec.

“Users gain many benefits when fillers can be combined with our Blomax stretch blow molder to form a compact block system,” says Thomas Redeker, sales director for Dairy Europe at KHS. The flexible and compact filling and packaging systems from the KHS Group cut down on space, are safer and more reliable and provide greater energy efficiency. For sensitive applications the new block systems can be provided as rotary or linear setups. Here, the sustainable filling technology can be expanded to suit customer requirements and is thus rapidly available on the market. This in turn caters for current trends: whether yoghurt drinks or breakfast on-the-go, the demand is for increasingly diverse products and packaging.

Flexible systems for all applications
In this context “sensitive” refers to an extremely gentle non-carbonated filling process. Here, it is not important whether fruit juices, dairy or liquid food products are to be filled, whether ultraclean filling, extended shelf lives or aseptic filling are required. Should an additional function be required at any time in the future, this can be easily retrofitted with the modular systems from KHS. “We’ve rounded out our portfolio for the sensitive segment and provide systems for many types of application,” states Redeker. Customers thus immediately profit from an even greater range of options.

When it comes to chunk filling KHS has extended its portfolio to include its own chunk dosing unit which enables pulp with chunks measuring 10 x 10 x 10 millimeters to be gently filled. The new dosing unit can be installed on all linear systems and supplements the existing filling system. This new innovation will be on display in Cologne. Another focus of the trade show will be the individual production of PET packaging, also in combination with the FreshSafe PET® coating system, which unites the advantages of both glass and plastic in one bottle to protect the product.

Focus on sustainability and resource efficiency
“There is a clear consumer trend towards PET,” explains Redeker. “In the food sector, too, where glass filling was standard to date, manufacturers are increasingly favoring flexible, lightweight plastic.” KHS has a special system for the flat, oval PET containers which are frequently used for products such as ketchup or edible oil: for containers like these a special heating method known as preferential heating ensures optimum material distribution and bottle quality. Very precise neck orientation is even possible specific to the application.

With its Bottles & Shapes™ program KHS also provides individual support to all those looking for the best possible PET packaging for their products. In addition to the lightweight bottles for still water recently produced or the PET bottle with a screw cap for highly carbonated beverages, KHS has convinced the market with its 1.0-liter bottle for milk and mixed milk beverages which weighs just 20 grams. Together with the University of Applied Sciences in Münster KHS has also developed a number of future-proof bottle design concepts.

Service concept further developed
In order that everything runs like clockwork for customers also after their purchase, KHS attaches great importance to outstanding service too. To this end its preventive maintenance concept for aseptic machines, which offers fixed maintenance modules at fixed prices, has been optimized and further developed. This has the advantage that the customer can plan and calculate its costs even better.

Also on show at Anuga FoodTec – but not at the KHS booth – is the KHS compact Innoket Roland 40 labeler. It can be fitted with various labeling stations to dress a whole range of containers from food cans and jars to glass bottles. The Innoket Roland 40 is characterized by its ease of use and the accustomed high standard of quality offered by KHS. The system, which outputs 2,500 to 25,000 containers per hour, can be viewed at Florin Gesellschaft für Lebensmitteltechnologie mbH at booth E20/F29 in hall 10.1.
(KHS GmbH)

Newsgrafik #33362

KHS - Prof. Dr.-Ing. Matthias Niemeyer is leaving the company at his own request   (Company news)

On December 31, 2017, Prof. Dr.-Ing. Matthias Niemeyer (photo), chairman of the Executive Management Board at KHS GmbH, is leaving the company at his own request to face new challenges elsewhere.

On December 31, 2017, Prof. Dr.-Ing. Matthias Niemeyer, chairman of the Executive Management Board at KHS GmbH, is leaving the company at his own request to face new challenges elsewhere. In his years in this post he has sustainably furthered technological product development, made an important contribution to significantly increasing sales and bringing about a number of considerable improvements for both the KHS Group and its customers. The Supervisory Board of KHS GmbH would like to thank Professor Niemeyer most sincerely for his committed and successful work in the service of the company. We wish him all the best for the future and continued further success in both his private life and professional career.

Until a final decision has been made regarding the new appointment to the post of chairman of the Executive Management Board, Mr. Burkhard Becker shall assume the position of chairman of the Executive Management Board of KHS GmbH in addition to his role as member of the Salzgitter AG Executive Management Board.

The further members of the Executive Management Board of KHS GmbH, Prof. E.h. Dr.-Ing. Johann Grabenweger (Sales and Service) and Martin Resch (Finance, Purchasing, IT & Legal Affairs), shall continue to perform their duties as before.
(KHS GmbH)

Newsgrafik #33266

New system for still water in single-serve formats: the KHS InnoPET TriBlock Aqua M  (Company news)

-Tailor-made for growth market water
-Space-saving blocksystem with many innovations
-Neck handling and the InnoPET Silent TipTainer for added value

With its InnoPET TriBlock Aqua M the KHS Group is presenting a compact, powerful block system for single-serve formats. The high-performance unit is specifically geared towards the growth segment of water in single portions – perfect for any handbag. It processes container sizes of between 250 and 800 ml at a rate of up to 50,000 bottles per hour. Thanks to the many innovations and compact size of the machine KHS customers can not only save on resources but also improve the quality of their products.

“With this system we’re offering more than just the compact version of the single machines. With the KHS InnoPET TriBlock Aqua M our customers get real added value,” says Arne Andersen, global product account manager for the TriBlock at KHS. The new system blocks the further developed Blomax Series IV stretch blow molding module, a labeling module and the Innofill PET NV filler. Together they form a unit which is perfectly suited to the application on hand, manufacturing bottles from preforms and then labeling, filling and capping them. Further advantages of the machine according to Andersen are its exceptionally hygienic design and optimized housing. The machine is centrally controlled by the improved HMI (human machine interface) on a clear 21.5-inch monitor with full HD resolution for detailed visualization of the process graphics. Another aspect which is especially important for practical operation is the consistent drive and operator concept with which KHS boosts effectivity and the level of convenience.

Optimized process steps
The individual modules on the TriBlock give optimum performance at every stage in the process. Compared to the previous model, the further developed Blomax Series IV has blow stations on which small bottles with a maximum diameter of 75 millimeters can be blown. The low level of noise pollution also deserves a mention here, this ensured by the aforementioned InnoPET Silent TipTainer; with its closed system and lower PET preform drop height the latter are fed especially gently and thus less noisily to the sorting unit.

The labeling module is distinguished by its robust design and thus a high degree of reliability and availability. A special vacuum system permits materials of a very low thickness to be used for the bottles and thus helps to cut costs. In addition, the top-drive technology, which consistently feeds the bottles through the TriBlock by their neck rings, also has many benefits: it is gentle on the PET bottles, minimizes downtimes and is advantageous when making lightweight containers as these are no longer exposed to any compression force in the labeler.

Low maintenance effort cuts costs
A new generation of valves in the filler shortens the filling time so that fewer valves can be used for the same total filling capacity. By focusing on smaller bottles and through the subsequent reduction in pitch, the diameters of both the filling wheel and ring bowl have been decreased. This makes both the filler and the TriBlock as a whole more compact. Users profit from a reduced maintenance effort and cuts in maintenance costs.
(KHS GmbH)

Newsgrafik #33228

EPBP approval: Direct Print Powered by KHS™ certified and fully recyclable  (Company news)

-Direct digital PET bottle printing process recertified
-Sustainable, environmentally-friendly packaging system
-Long-term cost benefits in materials and storage

Innovative technology which is fully recyclable: the first digital Direct Print Powered by KHS™ printing process for PET bottles has now again been certified by the European PET Bottle Platform (EPBP). This is the second sustainable and environmentally-friendly innovation from KHS and NMP Systems to be approved by the initiative within a very short time indeed.

Until fairly recently it was impossible to imagine that printed bottles could find their way into the recycling process. However, the research carried out by KHS and its partners on development in this field has since paid off: Direct Print Powered by KHS™ has again been granted interim certification from an official body. The recyclability of the award-winning direct printing process was first certified by the EPBP in 2013 and has now been reconfirmed. This means that an independent organization has clearly attested that PET bottles processed by Direct Print Powered by KHS™ have no negative impact on the rPET and are thus officially approved for bottle-to-bottle PET recycling.

During development the experts had to overcome one specific challenge before the printed containers could be certified for the recycling process. “The washing water must not be contaminated during the recycling process,” explains Martin Schach, head of the Printing Technology Department at KHS GmbH. “The ink must also not deposit itself on the crushed PET bottles.” KHS has managed to develop a digital printing process with low-migration, LED UV-curing inks for the food-safe decoration of PET bottles where the print reliably flakes off during the recycling process.

More quality, greater performance
Current laboratory tests for the Belgian market, where recycled PET bottles were examined for chemical residues in random checks, confirm the safeness of the process. Here, printed PET bottles from Martens Brouwerij had been fed into the recycling chain. In 2015 the Belgian brewery was the first beverage producer to launch PET bottles with Direct Print Powered by KHS™ to market and make use of the technology which has since been constantly further developed for the customer. These further developments include a higher print quality and new forms of decoration, resulting in a level of flexibility which enables the print on each separate bottle to be individualized through the use of different motifs. An additionally developed printed image inspection system is also to ensure the standard of quality at an even higher level of industrial performance.

In addition to the attractive marketing options this offers the end customer Schach sees a number of other advantages for customers. “Costs for production will fall in the long term as there’s no longer any need for labels and the storage thereof and no more adhesive is needed. Direct Print Powered by KHS™ stands for revolutionary technological advance and is also a step forward when it comes to environmental issues.”

KHS gives its customers sustainability
As a global company KHS continues to do justice to its pioneering role regarding sustainability and with its innovations supports the beverage and food industries in the protection of the environment. Besides Direct Print Powered by KHS™ Nature MultiPack™ by KHS and NMP Systems was also recently granted interim approval. In this form of packaging PET bottles no longer require a secondary packing of film as they are joined and held together by dots of adhesive only. This specially developed adhesive has also been certified.
(KHS GmbH)

Newsgrafik #32938

Big time saving during format conversions: KHS enables fast conveying mandrel changeovers  (Company news)

In developing a new fast changeover concept KHS has greatly reduced changeover times on its InnoPET Blomax stretch blow molders.

-Changeover time reduced by more than half
-All Blomax systems retrofittable
-Already successfully established on the market

In developing a new fast changeover concept KHS has greatly reduced changeover times on its InnoPET Blomax stretch blow molders. The optimized active mandrel now enables format changeover times to be reduced by more than half for all standard neck designs. This new option is of interest to all beverage producers who bottle products with different types of neck.

During a format changeover operators not only switch over the blow molds but other components as well. The conveying mandrel in particular is of especial significance in this process as a full changeover of these format parts was extremely time consuming to date. “Depending on its size a high-performance Blomax stretch blow molder can have around 280 conveying mandrels,” explains Marco Böhnke, product manager for stretch blow molding technology at KHS. When a product is changed over during beverage production and requires a change in the type of bottle neck, to date each individual mandrel had to be exchanged in its entirety.

As part of KHS’ constant striving to improve its lines and machines the systems supplier has now developed a variant which is much quicker to replace, making changeovers ergonomic and tool free without any great force being required. Besides the conveying mandrels the shields, grippers and other parts can now also be easily switched over using quick-change mechanisms; in some cases these can be adjusted without any installation work being required by simply rotating the part. Thanks to the above measures formats can be changed over in less than half of the time operators used to need.

In its new development KHS has retained its tried-and-tested active mandrel design. “The optimized changeover process is distinguished by the fact that only the actual format part, i.e. the mandrel head itself, is replaced, with the entire mandrel mechanism left untouched. This enables customers to save money and gain valuable production time,” states Böhnke, as a mandrel can now be replaced in about five seconds.
Uncomplicated retrofits

The new procedure can be easily retrofitted on any InnoPET Blomax Series IV stretch blow molder as following one-time adjustment of the conveying mandrels no further mechanical or electrical conversion of the machine is required. One KHS customer has already subjected the quick-change process to successful long-term testing. The system is also to be installed at a company on the German market in the near future.
(KHS GmbH)

Newsgrafik #33114

More than 76,000 visitors—drinktec 2017 smashes all the records!  (drinktec 2017)

- Record number of exhibitors as well
- Internationality expands again
- The world’s most important innovation and investment platform

With over 76,000 visitors from more than 170 countries, drinktec has chalked up the best-ever result in its 66-year history and surpassed all expectations. The number of visitors rose by 10,000 over the previous event in 2013. In particular at the international level, where drinktec is already very strong as it is, the trade fair was able to grow attendance again, this time by 12 percent. The ratio of visitors from outside Germany thus rose to 67 percent. The number of exhibitors increased to 1,749 from 80 countries—likewise a new record. That is mainly attributable to the wine technology trade fair SIMEI, which was held as part of drinktec for the first time, as well as further growth in the number of exhibitors at drinktec itself.

“World’s most important innovation platform”
In view of these record figures, Dr. Reinhard Pfeiffer, Deputy CEO of Messe München, spoke of an “outstanding result. drinktec has proven itself to be not only the world’s most important innovation platform in the industry, but also the most important investment platform. The cooperation with the wine technology trade fair SIMEI is a tremendous gain. I’m especially delighted that exhibitors here at SIMEI obviously encountered the international audience they expected.”

“The best drinktec ever”
The verdict of Volker Kronseder, President of drinktec’s Advisory Board and Chairman of the VDMA’s Beverage Machinery and Dairy Technology Association, after the five-day fair was also extremely positive: “For me, it was the best drinktec ever. Particularly interesting aspects were that SIMEI was integrated in drinktec for the first time and a new record for the number of exhibitors was set. We were able to achieve a high degree of internationality again, with many high-ranking visitors. This trade fair will give the global beverage and food industry a major boost for the next four years.”

“Expectations surpassed”
Richard Clemens, Managing Director of the VDMA’s Food Processing and Packaging Machinery Association, was also enthusiastic: “drinktec once again surpassed our high expectations. We’re over the moon at the international spread and expertise of the visitors! drinktec is a trend-setter: Visitors’ focus was on innovative solutions for tomorrow’s applications.”

Ernesto Abbona, President of Unione Italiana Vini (UIV), drew the following conclusion for his association: “We’re very proud that SIMEI has transcended its national boundaries and, together with drinktec, has opened the door to internationalization for our companies. I’ve spoken with a number of our exhibitors over the past days and they all agreed that the trade fair was a success. We were able to address new target groups from the southern hemisphere who we would otherwise probably not have been able to reach. As expected, the grape harvest reduced the number of winemakers who attended from some European and North American countries.”

drinktec exhibitors: “The trade fair to beat them all”
Exhibitors gave a first-class verdict of drinktec 2017, stressing the outstanding importance of the trade fair for the entire industry (see also “Exhibitor testimonials on drinktec 2017”). KHS Chairman, Prof. Dr. Ing. Matthias Niemeyer, regards drinktec as a platform “for the whole industry and experts worldwide. drinktec offers exhibitors perfect conditions for showcasing products and innovations.” Christoph Klenk, CEO of KRONES, spoke for many of his colleagues when he said: “All in all, drinktec is for KRONES the trade fair to beat them all. We’re very satisfied.” In the view of Gianfranco Zoppas, Chairman of SIPA, drinktec is the “benchmark for our industry. We’re extremely satisfied, not only with the number, but also with the quality of our visitors.” Dr. Rainer Brambach from EnviroChemie stated: “drinktec manages to bring together movers and shakers from all over the world—this concentration is unique for us.”

“SIMEI in Munich is a gain”
The fact that interest among visitors for wine, sparkling wine and spirits doubled (the number of mentions rose to 17,480) was mainly due to the exhibition area for SIMEI. This first-ever cooperation between drinktec and SIMEI was also rated positively by exhibitors at SIMEI. Marzio Dal Cin, President of Anformape (National Association of Machinery Suppliers and Products for Winemaking), summed up the feedback from his members who exhibited there as follows: “The impression among SIMEI’s exhibitors is very good for the most part. The presence of many international visitors, in particular from the southern hemisphere, is a very positive aspect and the reason why the companies believe in this project.” Cristina Bertolaso from the company of the same name expressed a similar opinion: “SIMEI in Munich is a gain because it has brought us a lot of new potential customers. We’re ready to conquer new markets.” Carlo Gai, the head of GAI, noted: “Italian wine technology is respected worldwide and we should definitely seize the opportunity to present it to such a large international audience.”

Success for oils+fats—higher attendance from the liquid food segment
The decision to integrate oils+fats, Europe’s only trade fair for the production and further processing of vegetable and animal oils and fats, in drinktec was a resounding success. 49 exhibitors from 16 countries presented themselves in Hall C1. The synergies with drinktec were primarily in the area of liquid food, where often similar machinery and components are used. The combination of drinktec and oils+fats met with a positive response from trade visitors, as also evidenced by the number of visitors from the liquid food segment: an increase from 8,700 to 10,700 or 22 percent.

PRO FachHANDEL, the leading trade fair for the entire German convenience and specialized beverage industry, was also held as part of drinktec 2017 for the first time. As a result, drinktec forged links with the specialized beverage sector.

The top event for visitors from all over the world
In particular the number of visitors from overseas is testimony to the fact that drinktec is a worldwide event and is rightly regarded as the industry’s global economic summit. The number of visitors from China was more than 2,000, an increase of 65 percent. That means China already occupies second spot in the rankings of the top 10 countries of origin for visitors—behind Italy, which likewise recorded a sharp increase thanks to SIMEI: by around 45 percent to 5,240 visitors. There was also a striking rise in attendance from South America. SIMEI apparently helped boost the number of visitors from Argentina to 545 (an increase of 165 percent). 1,100 visitors came from Brazil, a rise of 40 percent. France, likewise a wine country, came fourth this year with 1,800 visitors. Apart from Italy, China and France, other countries in the top ten were Russia (1,857 visitors), the UK (1,619), the U.S. (1,570), Austria (1,567), Spain (1,254) and the Netherlands (1,221).

Top marks for the supporting program
As in previous years, drinktec again earned outstanding plaudits from visitors. Almost all of them (97 percent) rated the trade fair as “excellent to good” and 96 percent intend to return in 2021. The new exhibition areas also went down well. 88 percent of visitors voiced a positive opinion about SIMEI@drinktec and 93 percent praised the Home&Craft area. The numerous events in the supporting program—the networking platforms, awards, and the conferences and forums—also met with overwhelming approval. Brewers from all over the world were drawn, for example, to Place2beer, an attractive port of call for craft brewers in particular. One-in-five of all brewers who visited drinktec came from that segment. The Innovation Flow Lounge, which was created in 2013 especially for visitors from the fields of sales and marketing, attracted around 1,000 interested attendees from all over the world. The drinktec Forum in Hall A2 was also well-attended, recording around 1,300 visitors.
(Messe München GmbH)

Newsgrafik #32965

Big technology on a small scale: KHS builds compact can filler for craft brewers  (Company news)

Picture: Manfred Härtel, filling product manager for KHS in Bad Kreuznach, Germany

- For low to medium outputs of 10,000 to 48,000 cph
- Fast product and format changeovers possible
- Filler and seamer in compact plug-and-play design

Craft beers have long established themselves on the world market. The KHS Group is thus now offering a new can filler to meet the requirements of small to medium-sized brewing companies. The Innofill CAN Compact is designed for low to medium outputs of 10,000 to 48,000 cans per hour. This compact combination of filler and seamer is shipped to the customer as a complete machine in a single container and commissioned on site on a plug-and-produce basis without any need for complicated installation processes. KHS is thus making the technical innovations of its big machines available to the craft brewing segment in this area, too.

“Three years ago we launched a completely new filling system with our Innofill Can DVD series. Developed for larger capacities, we’ve now scaled this technology to meet the demands of craft brewers,” says Manfred Härtel, filling product manager for KHS at its production site in Bad Kreuznach, Germany. With its efficient CO2 purging system the machine enables extremely low oxygen pickup. Thanks to its patented purging process it also consumes about 30% less carbon dioxide than conventional systems. Craft brewers can now also profit from this feature with the compact version. The demand for an adapted model for smaller filling quantities is rising in particular among the producers of high-quality, individual beers in the USA where the craft brewing scene has been well established for many years now. Unlike its big brother, which can produce up to 132,000 cans per hour, the filler, seamer, control cabinet, valve manifold and paneling of the Innofill CAN Compact form a closed unit. All that needs to be done to install the new system is to connect up the piping, sources of energy and conveyors.

No flavor carryover during product changeovers
One of the innovative features of the Innofill CAN Compact is its extremely hygienic design. In particular, this includes a gapless bell guide with PTFE expansion joints (Teflon) and bells which are lifted and positioned fully electropneumatically to seal the cans – without any mechanical action from cams and rollers. This does away with the need for water lubrication, simplifies cleaning and promises a service life which is up to twice as long as before. KHS also uses PTFE materials in the filling valve, for example to seal the filling valve piston and in the gas membranes. Flavor carryover when changing the product to be filled is thus as good as eliminated. This is of especial interest to craft brewers who often brew a large number of different beers and also make mixed beer beverages. The bell enables can necks from 200 to 206 to be processed. “We’ve managed to develop an uncomplicated piece of standard equipment which keeps procurement costs as low as possible,” says Härtel.

Product tank holds 200 instead of 500 liters
The new central product tank, which is installed at the top of the filler carousel and has a working volume of 50 to 200 liters, holds 300 liters less than the product tank on the big machines. Unlike in the latter plant technology, the tank does not rotate with the filler carousel on the Innofill CAN Compact. The beverage to be canned is supplied to the filling stations by a rotary distributor.

Electromagnetic inductive flow meters upstream of each filling valve permit exact filling volumes in the cans. The entire machine is very clearly structured and thus hygienic and easy to maintain.
(KHS GmbH)

Newsgrafik #32921

KHS Innoket Roland 40: new, compact labeler for craft breweries and spirits bottlers  (Company news)

With the Innoket Roland 40 (photo) the KHS Group is launching a compact labeler to market.

-Compact table machine for the low capacity range
-High-quality mechanical design based on the Innoket Neo
-Many expansion options for individual requirements

With the Innoket Roland 40 the KHS Group is launching a compact labeler to market. The machine will be premiered at this year’s drinktec trade show in Munich, Germany. The KHS Innoket Neo’s little brother has a capacity of 2,500 to 25,000 bottles per hour and is thus specifically tailored to the requirements of craft breweries and spirits bottlers. The Innoket Roland 40 can be fitted with various labeling stations and is characterized by its ease of use and the accustomed high standard of quality offered by KHS.

“The new machine is specially geared towards lines with a smaller output,” explains Cornelius Adolf, labeling product manager at KHS. During development particular attention was paid to simple operation and a high degree of economy. The table machine is not only of interest to craft breweries but also to companies in the food and non-food industries, such as manufacturers of canned food, pet food or shampoo.

In its standard version the Innoket Roland 40 comes with two cold glue stations. This allows shoulder and neck labels to be applied at two levels by the first station, for instance, with the second station affixing back labels to the bottles. Alternatively, self-adhesive stations, a combination of cold glue and self-adhesive technology and hot melt labeling processes can be used.

Proven components from the high-capacity range
Inside the Innoket Roland 40 are countless quality-determining components taken from the established high-performance KHS Innoket Neo labeling machine. These include the carousel, infeed and discharge stars, folding doors, installation and format parts and guides and on the cold glue station the gripper cylinder and label magazine. The servo feed screw found on the Innoket Neo has also been applied and integrated here, permitting gentle bottle stops.

Plenty of upwards scope
The new KHS development also provides many different opportunities for extension, enabling individual labeling tasks to be realized. It is possible, for example, to equip the Innoket Roland 40 with the KHS VarioDrive electronic bottle plate control system. Other options include mechanical alignment by side or base notch or swing-top closure in the infeed star and the fitting of traveling applicators, the latter used for cap or lid labels. L- and U-shaped labels – such as for the tax revenue stamps on spirits bottles – can also be labeled and rolled on. Optional sensors check for the presence of labels at certain points, for example in the label magazine or on the gluing roller, and for other factors such as broken bottles. With its many expansion options the KHS Innoket Roland 40 is thus perfectly suited to cater for all requirements in the small capacity range.
(KHS GmbH)

Newsgrafik #32797

Successful across the board: KHS Group again boosts turnover in 2016  (Company news)

-Total sales rise to €1.18 billion
-Further development of existing and launch of new systems in 2016
-Positive outlook for current year with clear areas of focus

The KHS Group has ratified its successful development of the previous year and again boosted its turnover, with sales totaling €1.18 billion last year. Its operating profit (EBT) significantly rose thanks to contributions from internal improvement programs to this end. Especially successful projects in Asia and Central America and a heavy demand for PET and can filling systems helped to promote sales. In the current business year the Group wishes to score further with innovations at the leading international drinktec trade show taking place from September 11 – 15, 2017, in Munich, Germany.

The ongoing development of resource-saving technologies and packaging systems will play a significant role here. Prof. Dr.-Ing. Matthias Niemeyer (photo), chairman of the Executive Management Board, places the focus on the Group’s role as an innovative driver of the industry. “Besides the very pleasing business generated by our existing systems and in service we now find ourselves on a broader footing compared to a few years ago thanks to the successful market launches of our innovations.” KHS’ service organization has been built up worldwide, for example, and consumables are now again directly included in the company portfolio. This added value, coupled with the Group’s reliable and very efficient lines, has generated a number of significant orders in all business areas. There is a growing demand across the entire range of filling and packaging machinery offered by the systems supplier: from PET through cans to glass and kegs, in practically all sectors from beer through soft drinks to water or sensitive beverages for hot filling. “This shows that we’re not only strong in one area but throughout the entire line business, where thanks to a high level of standardization we offer a very attractive portfolio,” emphasizes Niemeyer.

Examples of this include the growing demand for glass and canning lines on the company’s home market of Germany, successful implementation of PET block systems in the USA, India and Indonesia and the sale of several high-performance hot filling PET lines to South America and Africa. For many of the projects concluded in 2016 follow-up orders have also already been placed. According to KHS, this is primarily thanks to the consistent standardization of their product portfolio and the high level of expert advice given when answering customer queries.
Positive outlook for the current year

KHS wishes to boost the result it has again improved on even further. “We want to continue to be convincing, above all with powerful products and innovations which are geared towards our customers’ requirements and work reliably at their plants,” Niemeyer explains. In this context the systems provider also makes reference to its commitment to all of its stakeholders and will publish a new sustainability report this year.
(KHS GmbH)

Newsgrafik #32697

Trouble-free recycling: Nature MultiPack™ granted interim approval by the EPBP  (Company news)

Following tests on the Nature MultiPack™ the European PET Bottle Platform (EPBP) has confirmed that it can be fully recycled.

-European PET Bottle Platform tests Nature MultiPack™
-Recyclability of adhesive dot bottles confirmed
-Adhesive has no impact on rPET quality

Following tests on the Nature MultiPack™ the European PET Bottle Platform (EPBP) has confirmed that it can be fully recycled. The adhesive specially developed and supplied by NMP Systems and KHS has thus been granted interim approval for further market tests in Europe until June 30, 2019. The adhesive on the unique Nature MultiPack™ packaging system has no adverse effect on the rPET. Further tests shall be run to enable permanent approval to be granted.

As a form of packaging for PET bottles which does not require any visible secondary film packaging, Nature MultiPack™ attracted much attention during its presentation. The PET bottles are held together by dots of adhesive; there is thus no film obstructing the view of the bottle. In 2016 the system won the German Design Award for outstanding communication design and sustainable packing. Considerable savings in materials and practical handling distinguish the pack from all other existing packaging variants. With the interim approval granted by the EPBP an independent body has now also confirmed that in tests the specially developed adhesive for the dots of glue on the bottles has no negative impact on the quality of the recycled PET.

The tests showed that the dots of adhesive are removed as intended by friction during the washing process. The adhesive is then separated from the PET flakes as it floats to the surface of the cleaning medium. EPBP’s interim approval is valid until June 30, 2019. Further tests which are to culminate in the issue of permanent approval will follow in the coming months.

The EPBP is a voluntary, industry-related initiative which provides PET bottle design guidelines for recycling, among other information. It assesses new PET packaging systems and technologies as regards their effect on the recycling process and tests and certifies these according to strict guidelines.- It thus supports the European PET value chain with respect to economic and ecological sustainability.
(KHS GmbH)

Newsgrafik #32335

Proven standard: KHS Group ISO 9001:2015 certified worldwide  (Company news)

-TÜV Rheinland Cert GmbH audits production sites
-Certification according to new 2015 revision
-Employees proud of certification

With immediate effect the KHS Group’s production sites are now certified according to the new, revised ISO 9001:2015 standard. The current 2015 standard replaces the ISO 9001:2008 norm previously in widespread use. The KHS factory in Ahmedabad in India has been awarded the certificate for the first time. TÜV Rheinland Cert GmbH has now confirmed a uniform standard at all KHS production locations, giving customers of the manufacturer of filling and packaging systems the world over extra assurance.

“We’re extremely pleased about the successful expansion of the group,” smiles Hans-Joachim Peinemann, head of Quality Management at KHS. It is perfectly normal to have individual sites audited, he continues, but being certified group-wide is “very special”. In addition to its German production sites the KHS Group also manufactures its plant engineering in India, USA, Brazil and Mexico.

Customers and employees benefit
ISO 9001 stipulates the requirements made of a company-related system of quality management, the fulfilment of which acts as proof of conformity with defined standards. The practical application of these standards is verified by audits performed by an independent certification body. In the new, revised edition of the quality management standard from 2015 there is now an even stronger focus on continuous improvement and process and customer orientation.

Tested and verified worldwide
Standards which are usually easier for Europeans to adhere to can present something of a challenge on a global scale. “The project proved to be quite demanding at some sites. Other non-German plants have already been certified for years,” states Peinemann. He describes certification as a process which takes several years. ISO 9001 confirms that high standards are applied internationally. “Customers like to know for certain that they can rely on certain quality criteria. This certificate objectively confirms the KHS Group’s good system of quality management worldwide,” explains the QM expert.

Employee motivation has also increased following certification, he adds. Appearing together before a German TÜV auditor has internally heightened awareness of the common aspects the group shares. “For some of our factories it was like being presented with an award,” says Peinemann. For him, however, the standard is just one stage of many. “In the future we don’t just want to keep this standard but to build on it.” There will be time to do just that as the current certification is valid until 2019.

Supplementary certificates in Germany
The external auditors from TÜV Rheinland Cert GmbH have also attested to a uniformly high standard being upheld in energy, environmental and occupational health and safety management at all German KHS production sites. The latter are not only certified according to ISO 9001:2015 but also to ISO 14001:2015, BS OHSAS 18001:2007 and ISO 5001:2011.
(KHS GmbH)

Newsgrafik #32222

Commitment to young professionals: KHS cooperates with TU Berlin  (Company news)

The Technical University in Berlin is supplementing its laboratory facilities with the latest kegging technology from KHS.

-KHS kegging system for research and education
-Data analysis for further development at KHS
-Keg processing system in operation from February 2017

Photo: Prof. Dr.-Ing. Matthias Niemeyer, chairman of the KHS Executive Management Board (left), presented the keg system to Prof. Dr.-Ing. Frank-Jürgen Methner, head of the Department of Brewing Science at the TU Berlin (right).

The Technical University in Berlin is supplementing its laboratory facilities with the latest kegging technology from KHS. The new Innokeg AF1C1 for the semi-automatic processing of kegs (smaller barrels for the hospitality trade and industry), which was presented for the first time at this year’s BrauBeviale trade show, will give the university plenty of scope for application. At BrauBeviale Prof. Dr.-Ing. Matthias Niemeyer, chairman of the KHS Executive Management Board, presented the system to Prof. Dr.-Ing. Frank-Jürgen Methner, head of the Department of Brewing Science at the TU Berlin. The Innokeg prototype goes into operation on site next February.

“Universities and graduate schools train our up-and-coming young professionals. We’re thus very pleased to be cooperating more closely with the TU in Berlin,” says Thomas Matheyka, head of the KHS Keg Product Center. Jürgen Methner, who himself worked in the industry for over 17 years, has enjoyed close contacts with the filling specialists in Dortmund, Germany for many years. He recently appealed for help in equipping the new technology facilities at the Institute of Food Technology and Food Chemistry. KHS subsequently presented the institute with the modular Innokeg AF1C1 with one filling and washing element respectively and a cleaning tank. KHS also took care of the delivery, installation, commissioning and suitable training on the new system.

With the further developed version of the Innokeg KegBoy C2 for semi-automatic kegging, kegs made of both plastic and steel can be processed. Extra modules can also be added to the system. With the assistance of a new keg processor the TU can also precisely stipulate, record and analyze data from the filling and cleaning processes per remote control using a smartphone, tablet or PC. The Innokeg AF1C1 will be commissioned at the TU Berlin in the middle of February next year. The system will also be available on the market from this point forward.
For both education and research

The university is extremely pleased with the cooperation with KHS. “On the one hand our students will be trained on an ultramodern system and learn precisely how keg filling and washing function. On the other, with the help of this technology we can continue to push ahead with our research projects,” explains Methner. During their brewery and beverage technology course students will carry out filling and washing procedures on the system and test various quantities, media and cleaning cycles.

“Applying the experience gleaned on the academic side of things we can further develop the system for our customers,” says Matheyka. This interplay of education, research and industrial application is therefore something which benefits all those involved. As a potential future employer KHS is also helping students to make initial contact with the industry. “Students are very welcome to gain experience at our plants at the start of their practical module and write their bachelor’s or master’s thesis at our company,” states Matheyka. At the moment several dozen students are working on their theses with the help of KHS.
(KHS GmbH)

Newsgrafik #32211

Chopfab craft beer: a Swiss success story  (Company news)

The number one on the Swiss craft beer scene has been on the market for less than four years. With their instantly memorable name of Chopfab or “Heads off” (Swiss-German for “Bottoms up!”) Doppelleu Brewery’s top-fermented beer styles captured the mood of the moment so well that the next logical step in their career was to invest in a powerful and flexible keg racking system from KHS.

“Chopfab” or “Heads off” may sound rather violent but is in fact quite an innocent Swiss-German expression inviting you to flip the ‘head’ or lid off a bottle of beer before enjoying it. This friendly indigenous command inspired Philipp Bucher and Jörg Schönberg to name their new beer label Chopfab in 2012. The two young founders from Winterthur in Switzerland had little brewing experience when they started out yet were passionate beer drinkers with a background in business economics who were able to read the signs of the times. They noticed that the worldwide trend for craft beer had hit Switzerland a little late and thus set up Doppelleu Brewery, positioning themselves in the Swiss craft beer niche with Chopfab.

Their top-fermented specialty beers are aimed at a young target group geared towards enjoyment and lifestyle. “We now offer eight beers which are not too mad but easily drinkable and perfect for those new to craft beer,” says Bucher. Seasoned craft beer aficionados can try the six more creative brews. “Here, we also use more unusual ingredients, such as orange peel, coriander or ginger, to create very special flavors."

Philip Bucher is a sales and marketing professional with many years of experience under his belt. His concept of mouth-to-mouth propaganda and frequent visits to trade shows and events has paid off. After less than four years Doppelleu is the unchallenged number one on the craft beer scene in Switzerland. The brewery has thus had to increase its capacity an impressive three times from an initial 5,000 hectoliters to 100,000 hectoliters at the time of writing. Space therefore quickly became tight in the production shop; what the brewery needed was a powerful and flexible keg racking system – for after chiefly filling its beers into bottles and cans Doppelleu now wanted to gain a stronger foothold in the hospitality trade by selling its beer in kegs.

The KHS Innokeg CombiKeg fitted in perfectly with Doppelleu’s business concept. The machine’s compact and modular design combined with a high level of efficiency had the young businessmen immediately convinced. The infeed and discharge conveyors for the kegs are placed next to one another to save space; not just the interior washing and racking stations but also the exterior washing stations and media tanks are integrated into the system. Another enormous plus for the Swiss in their cooperation with KHS was that the Dortmund systems supplier pulled forward production at their plant in Bad Kreuznach in Germany for the brewery’s urgent order, readying the system for operation in Winterthur within a very short time indeed. Nothing thus stands in the way of many, many more cheerful cries of “Chopfab!” – without anybody losing their head in the process!
(KHS GmbH)

Newsgrafik #32199

KHS line design in 3D and virtual reality: efficient conception and on-site installation  (Company news)

KHS GmbH is consistently further developing its virtual line design program to include 3D visualization and a virtual reality (VR) environment.

-Mobile VR systems for customer line visualization on site
-Planners and design engineers linked up for fast changes
-Training scenarios for site personnel prior to installation

Photo: The 3D laser scan creates a seamless image of the environment from up to 200 scanned positions

KHS GmbH is consistently further developing its virtual line design program to include 3D visualization and a virtual reality (VR) environment. By linking up 3D programs and offer software all designs for orders and select customer offers can be created and displayed in 3D. A product data management or PDM system also networks planners and design engineers. Changes to the design become visible in the planning model and errors are ruled out. Customers benefit from a much shorter planning phase and more efficient on-site installation compared to standard 2D line design.

"On our 3D projection screens or Powerwalls the optimum line sequence and setup of machines are jointly planned with the customer. For example, we can recognize together in advance where there might be any collisions with third-party machinery in the production shop," says Thomas Riedel, head of Simulation and Virtual Reality at KHS. Since its launch in 2009 KHS has consistently developed its 3D line design program further and now offers mobile systems for visualization on customer premises. In the intercompany development of lines and machines international KHS design teams profit from that fact that the VR systems communicate with one another.

Behind the recording of the local situation at a customer site lie a number of complex processes. 3D laser scanning of 20 to 200 positions is required to gain a seamless image of the customer's environment, also in order that all shadow areas are logged – those areas which may be hidden by the existing plant infrastructure or suchlike. What is also crucial is that the 3D planning models of machines and conveying systems are managed and made available for virtual line design. "We have to make sure that we have the right 3D planning model on hand for every single 3D design model in the entire KHS machine program," says Riedel. This represents the machine in every possible formation for all variants and ordering options including the development history.

Plan and design models intelligently linked
KHS uses design engineering methods it has developed itself which ensure that the design model is semiautomatically linked up to the planning model through the PDM system. Changes to the design are made visible in the planning model and can then be updated in the 3D plan by a click of the mouse. "The system planner is thus directly linked to the designer through the PDM system – and planning errors are ruled out," says Riedel.

Customers benefit from this holistic planning, as the planning phase is considerably shortened. Unanswered questions can be clarified more quickly thanks to the 3D environment and on-site installation is much more efficient. KHS is currently working on virtual training scenarios for site personnel prior to assembly. This enables them to go through the individual work processes virtually so that they are better prepared for installation on site. VR simulation helps to provide simple access to and clearly visualize complex topics.
(KHS GmbH)

Newsgrafik #32128

New KHS Innofill Glass DRS filler boosts hygiene and efficiency   (Company news)

-Flexible filling system in the high capacity range
-Additional diagnostics option for quality assurance
-Optimized high-pressure injection results in less beverage loss

KHS GmbH expands its proven Innofill Glass DRS filler. The flexible inline machine for up to 75,000 bottles per hour provides very hygienic filling with low CO2 and product consumption. At BrauBeviale KHS is presenting a filler which with 132 filling stations will output up to 50,000 bottles of beer per hour for Badische Staatsbrauerei Rothaus AG. This is the second machine KHS has supplied to Rothaus. KHS has improved the popular filler by including many new features and options, such as the new pressure sensor or optimized high-pressure injection.

"The KHS Innofill DRS is the first machine to use pressure sensors in every single filling valve to ensure full monitoring of the filling process," says Manfred Härtel, filling product manager at KHS.

The sensor data is displayed as a pressure graph on the monitor. "This gives operators the chance to detect errors as quickly as possible," states Härtel. In practice this not only makes repairs easier and relieves operator workloads but also provides a basis for preventive maintenance. This data enables results to be statistically evaluated, with the help of which future sources of error can be pinpointed in advance. This in turn ensures consistent quality and the continuation of ongoing operation.

High-pressure injection optimized
In order to minimize the beer's oxygen pickup, in modern filling systems air is forced out of the bottle prior to closure by a jet of water being briefly injected to foam the beer. This foam displaces the oxygen in the bottle but also causes beer loss. Thanks to foam measurement via a camera and thanks to the central fill level adjustment unit the Innofill Glass DRS now reliably permits extremely precise filling volumes, thus minimizing beverage loss during this process. The operator no longer has to visually monitor the proceedings as the camera on the crowner checks and records the foam formation. Here, too, the data collected is statistically assessed. Operators are informed by the system if there is either too much or too little foam and badly foamed bottles are automatically channeled out. An intelligent post-regulation unit is also available as an option. Optimized high-pressure injection can be retrofitted – not just on all KHS systems but also on fillers made by third-party manufacturers.

Cleaning and filling optimized
Another new feature on the KHS Innofill Glass DRS is the hygienically optimized crowner which is now even easier and quicker to clean. For instance, the contact area on the head piece to the capping ring has been considerably reduced. This allows more forceful rinsing and reduces the amount of residual beer on the components. In order to decrease the contact area between the cork shoe and head piece, KHS has enlarged the distance between the two. In addition, a special sealing ring prevents beer entering the thread of the crowner.

Improvements right down the line
The shorter conversion times enabled by the new quick-lock system for format parts allow a considerable amount of time to be saved, resulting in higher machine availability. A new valve manifold also makes a separate control cabinet superfluous. All process valves and the entire sensor technology are now perfectly monitored. The operator can directly recognize the status of the process valves through local status indicators. Systems supplier KHS has improved hygiene in the surrounding area by doing away with active grease distribution in the filler carousel. The machine is now height adjusted without lubricants; grease distribution is thus no longer required. The redesigned media distributor means that the media storage and lubricant-free process seals in the media feed are physically separated from one another.

As a systems provider KHS has at its command a wealth of expertise that goes far beyond optimized filling processes. For example, the manufacturer of filling and packaging systems provides brilliant results prior to filling with the Innoclean bottle washer; downstream of the filler the module-based Innoket Neo system solution flexibly masters all kinds of labeling tasks.

The Innofill Glass DRS is just one of many machines KHS has at its disposal for the competent and sustainable installation of turnkey glass, canning or PET lines.
(KHS GmbH)

Newsgrafik #32120

KHS develops ultralight 0.5-liter PET beer bottle with Bottles & Shapes™  (Company news)

-From 22.5 to 20.9 grams per bottle
-Bottle weight for pasteurized beer reduced to 22.5 grams
-Numerous material and energy savings

At the behest of a major German brewery KHS GmbH has now developed the lightest 0.5-liter PET beer bottle in the company's history to date. Thanks to the lightweighting expertise in the KHS Bottles & Shapes™ program, in the future bottles for beer and malt beer can be produced much more cost effectively while saving more resources. Here, the systems supplier of filling and packaging technology successfully kept to its remit of not changing the bottle design.

The finished PET bottle is not only of the highest quality but also much lighter than its predecessor. Despite the lower use of resources the lightweight PET bottles boast undiminished high stability. "In order to achieve these optimum weight properties we exploit the concentrated expertise in our Bottles & Shapes™ program. This allows us to save on materials in both the bottle body and thread," explains Christian Rommel, project engineer for Bottles & Shapes™, when talking about the design process. KHS has made the neck ring much smaller and reduced the wall thickness in the neck and thread. Optimizing the thread has not affected the fitting accuracy and sealing properties of the standard PCO 1881 closures – in accordance with customer specifications. The processability on the existing line has also not been impaired. KHS has now cut down the weight of the brewery's previous 0.5-liter PET beer bottle by 1.6 grams to just 20.9 grams.

On the malt beer PET bottles for filling, which have to be able to cope with a higher internal pressure as the malt beer is pasteurized, KHS was able to save 1.5 grams. The weight of this bottle thus dropped from 24 to 22.5 grams. The weight-optimized bottles were extensively tested according to the given specifications in comprehensive laboratory and production tests.

Combination of expertise and convincing technology
The network of expertise provided by KHS Bottles & Shapes™ was instrumental in the successful development of the preforms. In close cooperation with the brewery's supplier KHS applied its competence in lightweighting during development and at the same time satisfied the customer's individual requirements. The bottler can now produce more profitably and efficiently while saving more on resources.
(KHS GmbH)

Newsgrafik #32000

KHS preform dedusting boosts product safety at Gerolsteiner  (Company news)

-PET preforms cleaned and not rejected
-Fewer rejects cut costs
-Retrofits for Blomax series III and IV possible

Gerolsteiner Brunnen GmbH & Co. KG boosts its product safety in the manufacture of PET containers with the help of a preform deduster from KHS. By cleaning its PET preforms the company cuts costs and also improves quality in the production process. Any foreign bodies are gently and reliably removed prior to the stretch blow molding process.

PET preforms can be soiled for a number of reasons. Sometimes particles such as PET dust or foreign bodies, including splinters of wood or fragments of PET, can enter preforms during production, transportation or storage. "If foreign bodies like these are detected during preform inspection, the preform is rejected," explains Marco Böhnke, product manager at KHS Corpoplast. Although the rejection rate for soiling of this kind is usually under half a percent, even this very slight amount is soon noticeable at a high production volume. A preform may only cost a few cents but by dedusting preforms and thus preventing unnecessary rejections annual savings into five figures can be made. The mineral water bottling plant in Gerolstein in Germany has now opted for this system.

To save costs for preforms which would otherwise be lost Gerolsteiner has placed a dedusting unit from KHS upstream of its inspection system. After six months in operation Dieter Kuhl, production manager for one-way containers at the bottling plant, is very pleased with the new extra. "We're constantly working on improving the quality of our products. Further developments in inline quality control also help us here. We're one step nearer to this goal with our dedusting unit and in addition we're cutting our costs in the long term."

The principle itself sounds pretty simple; using a compressed air lance specifically inserted into each preform the compact system removes unwanted particles at a rate of up to 81,000 preforms per hour. As a result not only are considerably fewer PET preforms lost; the risk posed by contaminated preforms is minimized further in combination with an inspection unit.

"KHS preform dedusting is a prudent addition to any quality assurance setup," says Böhnke. The deduster is upstream of the stretch blow molder and compactly integrated into the machine layout. The cleaning system is supported by an effective extraction unit which reliably ejects all particles into an easy-to-clean collection vessel. The cleaning module has been designed so that it can be retrofitted for all customers with InnoPET Blomax stretch blow molders in series III and IV.
(KHS GmbH)

Newsgrafik #31915

From filling to packaging: produce flexibly and sustainably with KHS  (Company news)

- Improved glass filler for more efficiency and monitored quality
- New keg modules make production future proof for craft brewers
- Efficient and sustainable packaging solutions

More than just standard: the KHS Group offers visitors to this year's BrauBeviale in Nuremberg, Germany, more flexibility in all fields of application. From November 8 to 10 the systems provider will have sustainable systems for the entire production process on display. Whether glass, PET, cans or kegs, KHS will be informing visitors as to its new developments in Hall 5, at Booth 5-147. The big highlights will be the Innofill Glass DRS glass bottler, racking and washing modules for craft brewers and packaging systems in cooperation with Gerhard Schubert GmbH.

"For us, this trade show is a highlight towards the end of the year. We're looking forward to three interesting days, as we're convinced that with our products we can offer customers in medium-sized and big companies in particular real added value," states Prof. Dr.-Ing. Matthias Niemeyer, chairman of the KHS Executive Management Board. Thanks to a host of new features KHS permits even more flexibility, sustainability and efficiency in production.

Glass bottling in the high capacity range
For reliable beer bottling KHS has further developed the tried-and-tested Innofill Glass DRS in time for BrauBeviale. At the show the company will be presenting the filler with a camera-controlled high-pressure injection unit, which minimizes beverage loss during filling, and with a new pressure sensor in each filling valve for full monitoring of the filling processes. Both developments ensure the filling quality of each processed bottle with minimum oxygen pickup and low CO2 consumption. At BrauBeviale KHS will have a filler that processes up to 50,000 bottles of beer per hour on show.

System grows with the client
Craft brewers, on the other hand, often produce a number of different beers on one system. They thus need flexibility in production. KHS has now designed several new modular keg systems especially for this target group which thanks to their many expansion options enable breweries to react flexibly to new demands. These modules are available as the Innokeg AF filler, which processes up to 50 kegs per hour, and the Innokeg AC washer which satisfies the highest demands for hygiene. Their modular design allows machine capacities to be expanded as the brewery grows.

Flexible and individual packaging
Both medium-sized and large breweries are increasingly relying on flexible secondary packaging systems. The partnership between KHS and Gerhard Schubert GmbH is now generating some particularly individual and flexible packaging options. At BrauBeviale both companies will be exhibiting a blocked system for the first time which already has a taker; Brauerei Schützengarten AG is now to take delivery of the new combination of a KHS packer blocked with a Schubert erecting and closing module. Merging the technologies of both companies brings about an increase in flexibility, quality and efficiency. Further details will be revealed by KHS at BrauBeviale.

NMP Systems, which is the KHS subsidiary for breakthrough innovation packaging solutions Nature MultiPack™ and Direct Print Powered by KHS™, will also be present. Visitors to KHS at Brau will experience firsthand the world premier Nature MultiPack™ launched by Evian in 2016. Live demonstrations of the Direct Print artwork platform for digital decoration of PET bottles will also highlight KHS leadership into the future of packaging.

Fast service boosts brewers' competitiveness
Time is the decisive factor when it comes to reacting to marketing demands. In its Bottles & Shapes™ program KHS thus implements many measures which facilitate shorter format changeovers. These range from further improved offer preparation processes through optimized warehousing to faster part production and assembly. This allows operators to realize new containers, packs and packaging more quickly and more efficiently.

The KHS Group will be presenting the above and many other systems for the beverage industry in Hall 5, Booth 5-147, at BrauBeviale in Nuremberg, Germany, to be held from November 8 to 10 of this year.
(KHS GmbH)

Newsgrafik #31851

All4Pack: KHS presents packaging of the future  (Company news)

-Focus on Nature MultiPack™ and Direct Print Powered by KHS™
-Direct sales from the pallet: KHS Innopack Kisters DP
-Resource-saving filling and packaging systems

At All4Pack 2016, from 14-17 November 2016, KHS GmbH will be presenting current highlights in plastic and secondary packaging, along with the latest innovations for PET bottle applications, Nature MultiPack™ and Direct Print Powered by KHS™. Furthermore, visitors will be able to discover a wide range of additional packaging systems.

One of the highlights at the trade show booth will be Nature MultiPack™. It was launched earlier this year in France and Belgium by Evian and won under the name ‘naked pack’ Le Grand Prix de la Stratégie 2016 for design and brand strategy. Nature MultiPack™ is based on specially developed adhesives which bond PET bottles together to form multipacks. Reducing secondary packaging by as much as 85%, the easily removable adhesive dots leave behind clean bottle surfaces, minimizing in-store and in-home packaging waste. Individually oriented bottles enhance brand presence and showcase bottle design, white tape handles bring convenience and convey marketing messages. Visitors to the KHS booth will have the chance to experience packs firsthand and learn more about the high speed industrial application.

Digital printing of PET bottles
KHS will showcase digitally printed PET bottles at the booth and provide the opportunity to learn more about how Direct Print Powered by KHS™ will enable brand owners to launch new bottle decorations within minutes. This disruptive innovation leverages highest possible image variability within future PET bottling lines. Based on specially developed low-migration LED-UV cure inks, Direct Print combines a secure cloud-based artworks management platform, with off-site sample printing for design and approvals. This technology is capable of 12,000 / 24,000 / 36,000 bottles/h.

Flexible systems for sustainable packaging
The presentation of goods in retail stores is a factor that plays a major role for sustainable packaging concepts. Sales directly from the pallet without repackaging onto shelves while maintaining excellent presentation and effective advertising placement at the point of sale are thus key requirements for many customers. The KHS Innopack Kisters DP display packer provides this flexibility for packaging and palletizing while saving materials and resources. It is also available in a block design.

In addition, visitors can find information on innovations such as the KHS InnoPET TriBlock block concept, packaging for the dairy sector and KHS Service. With InnoPET TriBlock, KHS has launched a filling and packaging system for PET bottles to market which incorporates a stretch blow molder, labeler and filler. With consistent neck handling it also enables lightweight PET bottles to be processed.

Look for KHS GmbH at Booth 6F029.
(KHS GmbH)

Newsgrafik #31845

Clean in every detail: the new, hygienic KHS crowner  (Company news)

-Increased microbial safety and simple cleaning
-Effective protection against oxygen penetration in beer bottles
-Simple retrofit into existing systems possible

KHS GmbH has developed a new crowner which is setting standards in hygiene in beer filling. By further developing a tried-and-tested system microbial safety has been increased and cleaning times have been shortened. KHS has been able to retain the crowner design and dimensions so that bottlers can retrofit the new element into existing lines using a conversion kit. With immediate effect all future systems will be automatically supplied with the new construction as standard.

"The crowner is a critical element as it constantly has to operate in beer residue. This is a challenge during operation which we've been able to considerably improve and alleviate," says Manfred Härtel, filling product manager for KHS. As in the beer filling process, also when closing a bottle oxygen must be prevented from entering the inside of the receptacle. If not, the beer undergoes oxidative change which causes it to develop an unwanted aging taste and also shortens the beverage's shelf life. The crowner element must also stay microbiologically clean during closure so that it does not contaminate the beer bottles.

The new KHS crowner improves hygiene and cleaning through a number of different innovations. For instance, the contact area on the head piece to the capping ring has been considerably reduced. This allows more forceful rinsing and reduces the amount of residual beer on the components. In order to decrease the contact area between the cork shoe and head piece, KHS has enlarged the distance between the two. This enables optimum flushing. In addition, a special sealing ring prevents beer flowing into the thread of the crowner.

Thorough cleaning thanks to material savings
The crowner is always only cleaned with hot water or a foam solution from the outside. For this reason KHS has added two extra flushing openings so that the rinsing media can access the soiled areas inside the machine much better. "By removing material we're increasing permeability. This boosts microbial safety and shortens cleaning times without us having to compromise on function or stability," explains Härtel.

Not only sensitive craft and draft beers profit from these improvements; non-alcoholic beers do, too. The latter are hygienically even more sensitive as they do not have the sterilizing effect of alcohol.
(KHS GmbH)

Newsgrafik #31848

Coating process for soft drinks: KHS FreshSafe PET® triumphs in India  (Company news)

-Systems supplier with another large order for Plasmax technology
-Big demand for PET and glass lines in July
-Marked success in India, Central America and Southeast Asia

The KHS Group looks back on an exceptionally successful month. In July 2016 the Group, headquartered in Dortmund, Germany, was able to record several big orders. Much of this success was attributable to the sale of two FreshSafe® PET TriBlock lines to a major soft drinks producer in India. In combination with the lines the interior glass coating system is also being used on this important growth market.

Talking about the special follow-up order from India Prof. Dr.-Ing. Matthias Niemeyer, chairman of the KHS Executive Management Board, explains, "Each market has specific requirements which we can provide the right system solutions for, such as here." The major soft drinks producer will be using the innovative FreshSafe PET® coating system from KHS Plasmax on its two new PET lines. It is part of two compact TriBlocks, each of which consists of stretch blow molder, coating system and filler/capper combination. With FreshSafe PET® the PET bottles are given an ultra-thin glass coating while remaining fully recyclable. The process gives the containers it produces – in this case handier small 0.25-l bottles – much improved product protection. The technology has been in use as a single machine at the site in India since February 2016 and, thanks to its convincing advantages, has resulted in this follow-up order. The beverage producer achieves a longer beverage shelf life and is thus able to cover a greater distribution area. In this way companies can produce at a central location, in turn saving costs for warehousing and logistics. On large growth markets in particular, such as India, this is an enormous advantage for beverage producers. With the use of this innovative technology economic and also ecological aspects are combined, making production more sustainable.

One of the other systems KHS also sold in July was a high-performance PET hot fill line to Southeast Asia which is especially suited to the bottling of sensitive beverages. Orders for four turnkey glass lines in Central America were also received during the same period. These reliable systems are equipped with the powerful Innofill Glass DRS filler. All of these major projects will be completed in the shortest time thanks to KHS' use of standardized modules, machines and processes.

"Projects like these send out an important message;" says Prof. Niemeyer, adding, "our strategy continues to bear fruit and confirms that we are on the right course." In doing so the Dortmund company chiefly focuses on its extensive line expertise throughout the entire market, with its glass and PET lines in particular excelling in July 2016.
(KHS GmbH)

Newsgrafik #31632

200th BloFill from KHS goes to Coca-Cola subsidiary in Africa  (Company news)

The success story continues: Nairobi Bottlers Ltd in Kenya has now also opted for an InnoPET BloFill stretch blow molder/filler block (photo) as part of a larger complete package. This allows KHS to place the 200th BloFill system on the world market.

Nairobi Bottlers Ltd is a subsidiary of Coca-Cola South Africa Bottling Company (CC Sabco) Ltd. It is based in Nairobi, Kenya, and distributes its range of products throughout a region which constitutes about 50% of the country’s total area. The company already produces water and soft drinks in Nairobi. The new KHS block is now to be used to also produce the well-known Minute Maid and Minute Maid Nutriboost juices, among other products. KHS' InnoPET BloFill is perfectly suited to this kind of filling process. The new PET hot fill system can bottle sensitive products, such as juices with and without fruit chunks, teas and mixed milk beverages, at a rate of 28,000 containers per hour. It is important to the producer that no preservatives are used throughout the entire filling process. KHS has developed especially light PET bottles for the hot filling of the products at temperatures of up to 87°C.

Energy-efficient, space-saving system
In the InnoPET BloFill stretch blow molder/filler block the bottler in Nairobi has opted for energy-efficient stretch blow molding/filling/capping technology. With its sophisticated array of blow stations the blow molder is especially compact and designed to save plenty of space. The InnoPET BloFill not only produces low-weight PET bottles with optimum stability but also fills and caps them. The InnoPET BloFill stretch blow molder/filler block is designed for high capacities, achieving an output of up to 81,000 bottles per hour.
(KHS GmbH)

Newsgrafik #31603

Further growth in 2015: KHS increases turnover compared to previous year  (Company news)

-8.9% growth compared to 2014
-Total sales ran to €1.17 billion in 2015
-Vision of technological and service leadership still in focus

The KHS Group continues to grow: in 2015 the systems supplier increased its turnover by 8.9% compared to 2014. In total the company achieved an overall turnover of €1.17 billion, with the main drivers of growth being not only the European market but also those in Asia and the Americas, plus the further expansion of its service business. In 2016 KHS aims to further its market position in international business by readying its disruptive innovations for market.

"This positive development encourages us to continue to consistently pursue the course for innovation we have embarked on," emphasizes Prof. Dr.-Ing. Matthias Niemeyer, chairman of the KHS GmbH Executive Management Board. "It also corroborates the growing market demand for innovative and sustainable filling and packaging technology." After the revenues for 2014 had grown by a further 5.8%, in 2015 KHS increased its turnover by a total of 8.9%.

Asia and America with bigger sales share
To date Europe has been one of the main reliable markets in the company's development, with KHS generating about a third of its total turnover, namely 32%, on its home continent (2014: 35%). Other markets are also gaining in significance, however. In 2015 the share of sales at KHS grew in both Asia-Pacific and in the Americas. While Asia-Pacific now accounts for 28% of total sales (2014: 24%), the share on the American continent in 2015 was 26% (2014: 25%). Last year's sales in the Middle East and Africa also remained stable at 14% (2014: 16%).

KHS aims to grow with the market in 2016. "The year has got off to a promising start", states Niemeyer. With the successful implementation of Direct Print Powered by KHS™ the company from Dortmund has pushed the marketing of digital container dressing. The systems provider will continue to push the market entry of pioneering innovations, such as Nature MultiPack™, a form of beverage packaging which requires no film whatsoever which KHS successfully launched to market together with Evian in France in March of this year.

Cooperation and expansion of the service business
As presented at the last BrauBeviale trade show KHS' cooperation with Gerhard Schubert GmbH, the packaging systems manufacturer with the world's greatest experience in top loading, helps to expand the company's packaging portfolio. KHS is also boosting its capacities in its service business. As in the last three years the group has managed to further extend its network of service engineers.

"The aim of all of our endeavors is to save resources with sustainable innovations throughout the entire value chain of our customers. Through this concept we're convincing the market of our expertise in packaging. We will continue to adopt this strategy," explains Niemeyer.
(KHS GmbH)

Newsgrafik #31566

More than standard  (Company news)

The task: to provide a multifunctional labeling machine which is easy to operate and meets the high quality requirements of Poland's biggest brand of mineral water. The answer: the Innoket Neo (photo) from the KHS Group. Not one but three machines in this new series are in service at Nałęczów in Poland. One of the main reasons for the bottler investing in this particular piece of equipment was its free-standing labeling station concept which gives the operator optimum access and the highest possible level of safety.

Cisowianka is a natural mineral water which is filled directly at source not far from the Polish town of Nałęczów near Lublin. The region's extraordinary microclimate makes it a famous spa, its excellent air quality primarily valued by people with cardiovascular disorders who come here to take a cure.

The filler of this special water, ZL Nałęczów Zdrój, runs one of the most technically modern mineral water bottling plants in Europe. Founded in 1979 in Drzewce very close to Nałęczów, it has been drawing its water from a source about 100 meters below the ground for over 35 years. The company is proud of its high standards of quality and safety; it does not change the natural features of its water in any way. Outside Poland premium brand Perlage is the best-known Nałęczów water, filled into dark-blue bottles and exported to restaurateurs in many countries in Europe, America and Asia.

Specific system for particular demands
When it came to packaging its natural commodity the company did not want to make do with the usual standards and began looking for a specific system. It soon found that the KHS Innoket Neo series best satisfied its top-class labeling requirements. Available in six different sizes, it caters for a number of different labeling processes and capacity ranges. In Nałęczów the customer opted for a combination of cold glue and self-adhesive labeling, with the basic dressing consisting of paper labels for the front and back of the PET bottles. On this count the Innoket Neo is convincing with its rotating glue pallets which, together with many other innovations, permit very long labeling station maintenance intervals of up to 20,000 hours. This is equivalent to three to four years in three-shift operation. One of the special features of the equipment is the application of a self-adhesive shoulder label to the bottles. Downtimes during reel changeovers or faults are also prevented by redundant labeling units, thus ensuring machine availability. For maximum bottle protection the machine does without the otherwise usual, abrupt bottle flowgate; instead, the bottle flow is very gently moved through a feed screw which is driven by servomotors.

The customer uses the Innoket Neo to label Poland's leading Cisowianka mineral water brand in three varieties: still, medium and sparkling. On average 450,000 bottles are processed per day – which is well below the machine's maximum output, as Kamil Banaśkiewicz, technical project coordinator at ZL Nałęczów Zdrój, emphasizes: "We fill several hundred million bottles per year here at our plant, with our KHS labeler one of the most reliable machines in our production shop." The machine's use for these three concrete variants of mineral water is based on the specific requirements of the connected lines: the container material, the number of labels per bottle and the efficiency. The Innoket Neo series is of course also suitable for any other labeling task and filling line, so that the customer is currently talking about a further project. The variety of containers processed by the Polish bottler is infinitely larger; throughout its entire portfolio the sizes of container vary from 0.3 to 1.5 liters. There are all types of glass and PET container and can, from the classic PET bottle to the premium glass bottle. It is thus obvious why great attention is paid to flexibility with each new investment in plant engineering.

Details convincing
"For us, both the quality at KHS and the after-sales service were of equal importance," says Banaśkiewicz. The KHS Innoket Neo also had the client convinced with its various clever details. For format changeovers, for instance, the entire station can be extended by 40 cm on special runners. This provides access to areas which on standard machines are hidden inside the machine body behind other parts and only partially accessible. In addition, the entire label magazine is mounted on a swivel table, enabling the important magazine head to also be perfectly adjusted with its fixing clips.

Another definitive factor in the success of the project was the cooperative partnership during the planning phase which continued on into the fast commissioning phase and beyond, explains Banaśkiewicz, with the systems supplier from Dortmund in Germany putting together the best complete package.
(KHS GmbH)

Newsgrafik #31557

Direct Print Powered by KHS™ wins the prestigious EDP 2016 award for ‘Best Industrial ...  (Company news)

... Production Solution’ at drupa

-Digital decoration technology matches PET line speeds for soft drinks, water and beer
-Variable image capability provides unprecedented brand engagement

Direct Print is the first industrial-scale, digital printing process with low-migration LED UV-cured inks to provide a food-safe decoration solution for PET bottles.

Photo: The Direct Print team has the ability to fully test each new parameter industrially before taking them to the field.

Martin Schach, leader of the Direct Print Powered by KHS technology team stated that ‘the Direct Print industrial scale digital printing technology for PET bottles is the result of ten years’ investment in disruptive innovation by KHS, with many close technical partnerships from the world of high-tech digital printing, combined with highest precision design and manufacturing, resulting in more than a hundred and fifty patent applications along the way.’

Software matters
The cloud-based Direct Print software platform links a headquarters-based sample printer for 1-to-1 proofing and artworks design approvals, linked via the cloud with the workflow of the production site based Direct Print industrial printer. The industrial scale Direct Print equipment is capable of printing variable, high quality images on each bottle in PET filling and packaging lines running at 12,000 / 24,000 / 36,000 bottles/hour. The Direct Print technology platform will enable beverage companies to change graphics and individualize decorations within minutes instead of weeks, bringing a new medium for consumer engagement into the increasingly digital world of packaging. Over time, Direct Print will eliminate labels altogether, thus reducing materials, carbon footprint and time-consuming changeovers on higher flexibility filling and packaging lines.

Moving to market
MARTENS Brewery based in Belgium implemented the first Direct Print industrial prototype, which will soon be replaced with the next generation Direct Print industrial system with several additional technical features, variable image capability and higher quality final images.

Several other beverage brand owners are exploring the possibility to become early Direct Print implementers able to leverage this disruptive brand engagement packaging technology.

Phil Johnson, managing director of NMP Systems which commercializes the Direct Print solution, states that ‘receiving this exciting award for printing technology from the drupa and EDP organizations is especially gratifying for a technology solution which has been designed expressly for the Filling and Packaging world.’
(KHS GmbH)

Newsgrafik #31503

Coca-Cola uses customized hot fill system from KHS  (Company news)

-Hygienic bottling thanks to hot fill technology
-Individual system with special details
-Customer also pleased with range of services

Around the globe consumers are finding that juices and sports drinks are a healthy alternative to what are often rather sugary soft drinks. Bottlers who want to muscle in on this growth market have to satisfy the special technical demands made of the process and filling technology for such products. For its juice and sports beverages Coca-Cola Canners in South Africa has now opted for a high-performance hot filling line from KHS.

Photo: Coca-Cola bottles iced tea, sports drinks and juices with and without fruit chunks on the new line.

"The entire fruit juice and sports drinks segment is growing all over the world as health awareness increases among many consumers," states Steve Nagiah, plant manager at Coca-Cola Canners. It was decided to extend the company portfolio in the long term in order to develop this growth area. With its four canning and two PET lines the production site in Wadeville just outside Johannesburg is one of the largest of its kind in the world. 320 employees working round the clock make sure that around 350 million liters of near-water beverage Glacéau, sports beverage Powerade and the Coca-Cola, Sprite and Fanta brands leave the factory every year.

Hot fill technology for hygienic bottling
Coca-Cola now bottles iced tea, sports drinks and juices with and without fruit chunks on the new line. The new pulpy beverages could not be bottled on the two existing lines for PET bottles. "The technology required for this is more sophisticated," says Nagiah. Following a carefully considered consultation process Coca-Cola Canners decided to go for a system manufactured by its long-standing partner KHS. Especially the hot fill technology for hygienic bottling combined with an output of up to 48,000 bottles per hour had those responsible convinced.

"For this demanding project we developed a system which is precisely tailored to meet Coca-Cola's specifications," declares Philipp Casparby, project manager for KHS Manufacturing (South Africa) (Pty) Ltd., KHS' South African subsidiary. Like other KHS block systems, the new line covers all stages in production from stretch blow molding through filling to labeling, packaging and palletizing.

The key is in the detail, however; the line also processes fruit juices with a percentage of fruit pieces. These fruit chunks must not be damaged during filling; at the same time the low filling dosage tolerances must be adhered to. The company designed a line with two precision volumetric fillers. On this the fruit pieces are first bottled with a little juice before the second filler tops up the bottles with the rest of the juice.

The entire filling process makes use of hot fill technology where the content is heated to over 100°C and then filled at a temperature of about 83°C. This makes sure that microorganisms are safely eliminated. With the new line Coca-Cola Canners is able to fill up to 48,000 bottles per hour holding between 0.3 and 1.5 liters.

After almost two years the customer's summary is a positive one – not just with respect to the sustainable technology but also regarding the service provided 24/7. Nagiah reveals, "We thus recently ordered two more KHS packaging machines."
(KHS GmbH)

Newsgrafik #31462

Nature MultiPack™  (Company news)

In Nature MultiPack™ KHS has developed a system which bonds PET bottles together with adhesive dots. Specially developed for this purpose, the adhesives ensure excellent pack stability and consumers easily twist individual bottles off from the rest of the pack. A convenient handle which does not cut into the hand makes the pack easy to carry, and brings marketing messages and bar codes. Compared with conventional multipacks (shrink film, paperboard, plastic rings), Nature MultiPack has 85% less packaging material and up to 67% energy savings during production. Nature MultiPack delivers a clean and premium look and feel, with almost zero secondary packaging waste.

An innovative solution with a clear sustainability message!
(KHS GmbH)

Newsgrafik #31419

Energy costs practically halved: KHS converts stretch blow molder for Mineralbrunnen Teinach GmbH  (Company news)

Overheads for materials and the price of energy are among the biggest cost drivers in production. Mineral water bottlers Teinach GmbH have thus charged the KHS Group with the modernization of their PET bottle filling line. In the course of the process the systems supplier greatly improved the level of energy efficiency by optimizing the heater boxes on the PET stretch blow molder in particular.

Photo: The heater boxes are distinguished by new reflectors made of modern ceramics and a precisely adjusted geometry.

Non-alcoholic beverages in the Teinacher and Hirschquelle brand portfolio are the chief products for the company from the north of the Black Forest which belongs to Mineralbrunnen Überkingen-Teinach KGaA. At its plant in Bad Teinach, just under an hour's drive west from Stuttgart, the mineral water bottler achieves an output of about 150 million bottles of water and soda pop per annum, a third of which are made of PET. Preform heating consumes a lot of energy and is thus a relevant factor when it comes to the operating costs incurred during the manufacture of PET bottles. One of Michael Schanz's main tasks, head of Engineering at Mineralbrunnen Teinach GmbH, is thus to constantly monitor the energy efficiency of the lines. He was therefore immediately enthusiastic about the new possible savings offered by KHS' InnoPET machines. KHS analyzed the savings potential of the reliable InnoPET Blomax Series III together with the engineers from the mineral water company. The stretch blow molder in Teinach has been in operation since 2007. "Over the last nine years the machine has given us wonderful service. KHS then showed us that with little effort we could improve further on our levels of energy efficiency," Schanz explains. After a maximum of two days the machine would again be ready for operation, yielding savings of up to 50%. "After we'd discussed the details, it only took a few weeks before conversion started." This was possible as KHS was able to make use of a tested development from its energy-saving solutions product module.

Optimized heater box geometry with ceramic reflectors
The upgrade primarily consisted of converting the heater box on the Blomax Series III Compact where the PET preforms are heated for the downstream stretch blow molding process. Frank Goebel, head of Service Engineering at KHS, highlights the development of the past few years: "We have almost 600 Series II Blomaxes in operation worldwide. We aim to continue to support the operators of these durable machines even after many years of service." At Teinach this specifically means saving over 40% in energy by converting the heater box which KHS achieved by adding new reflectors made of modern ceramics to the heater boxes and precisely adjusting the geometry. Thanks to their special design the physical properties of the ceramic elements have a very positive impact on the energy distribution, resulting in less energy being needed to heat the preforms. The reflectors and infrared emitter are also built so that the sensitive bottle thread area is not unnecessarily heated. The amount of cooling in this area can then be reduced, thus saving Teinach even more energy. This higher efficiency often also makes it possible to shorten the heating segment, explains Goebel. If fewer heating elements are required in the heater, the infrared emitter consumption also drops as a result.

KHS usually converts the heater boxes on all Series III Blomaxes in a maximum of two days. KHS process engineers make the fine and final adjustments during the startup phase so that disruption to production is kept very short. Teinach's head of Engineering is suitably satisfied with his company's decision to invest in this new feature. "We're always trying to save energy to cut costs and protect the environment," states Schanz. The bottler demonstrates this outside the production shop, too, through its a long-term cooperation with the Central/North Black Forest Nature Park for the conservation of the unique local countryside, for example. Or with its system of energy management, certified according to ISO 50001. "We can simply read off the history of the heating costs for the modernized system on the electricity meter and document the significant savings," he claims. Schanz also adds that KHS converted the line quickly and competently without affecting system operation. Since the end of last year the revamped heater box has been running without any problems whatsoever.

Through the amount of energy saved, investing in a modernization of the InnoPET Blomax Series III pays off for users after one to three years depending on the line's capacity utilization and the price of electricity. KHS also offers the conversion for both versions of the Blomax Series II: the Modular or the Compact. "For many companies, energy-optimized PET stretch blow molders are an excellent way of reducing production costs," says Goebel. He expects more orders for this sustainable KHS conversion product in 2016.
(KHS GmbH)

Newsgrafik #31404

Improving oval PET bottles: higher quality with preferential heating from KHS  (Company news)

-High-quality appearance and optimized material distribution for oval shapes
-KHS system for new machines and retrofits
-Fast changeovers between round and oval bottles possible

Special bottle shapes make high demands of many stretch blow molders during production. The preferential heating system (PH) developed by the KHS Group now enables bottlers to achieve perfect bottle quality even with extremely oval bottles in an energy-saving, safe and reliable process. The systems provider now also offers this option for its successful InnoPET Blomax Series IV.

Regarding the energy-efficient manufacture of PET bottles the InnoPET Blomax Series IV stretch blow molder is one of the most powerful on the market. With preferential heating fillers of oval bottles benefit from a manufacturing process which KHS has been successfully applying in older series of stretch blow molders since the 1990s.

Homecare and personal care products in focus
In transferring the technology to the latest series of KHS stretch blow molders all the benefits over previous machines are retained. These include the much lower use of energy and the simpler design. Especially when processing items such as cleaning agents, laundry detergents or personal care products, which are very often filled into oval PET bottles, this process has many advantages.

"Without preferential heating the preform is heated evenly in the stretch blow molder," explains Marco Böhnke, product manager at KHS Corpoplast. "This means that the areas of the bottle which come into contact with the blow mold first cool down before the others." As a result, the PVC hardens at these points so that the material is distributed unevenly in the ensuing bottle. The walls are also thicker in these places. It is no longer possible to obtain as even a distribution of materials as possible and thus optimum stability and bottle quality in the ongoing stretch blow molding process. If, as is the case with preferential heating, a preform is heated selectively according to its later bottle shape, this undesired effect is compensated for.

Special heater segment for a selective heating profile
Preferential heating is made possible by a special heater section at the end of the heating segment. Here, the system first rotates the PET preforms through the heater to obtain a basic heating profile. In the downstream PH section rotation is stopped, giving the preform its selective heating profile. The new heater box specially developed for this application plays a big role here, transferring the required heating energy to the preform through two opposite heater levels.

"We're generally improving quality, especially the material distribution and stability of the bottle," says Böhnke. Another effect of preferential heating is that "Thanks to this intelligent technology we can realize material savings of up to several grams per bottle." This means that bottlers no longer have to use heavy preforms in order to achieve the same stability with an uneven distribution of materials without the PH process and can thus save on resources. The machine permits very fast changeovers to round bottles, too, which gives converters in particular great flexibility. Preferential heating can not only be used in every new InnoPET Blomax Series IV as an option; it can also be retrofitted into existing systems.
(KHS GmbH)

Newsgrafik #30930

Lightweight PET bottles make a breakthrough in South America thanks to KHS Bottles & Shapes™  (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)

Newsgrafik #30844

More flexibility for keg fillers: the KHS Innokeg Transomat 6/1  (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)

Newsgrafik #30831

KHS delivers new filling line for big cans to Tsingtao Brewery in China  (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)

Newsgrafik #30823

KHS wins World Beverage Innovation Award for lightweight 1-liter PET milk bottle   (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)

Newsgrafik #30717

KHS stretch blow molder pays off after two years  (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)

Newsgrafik #30647

BrauBeviale: KHS focuses on efficiency in energy and resources  (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)

Newsgrafik #30482

MARTENS Brouwerij brings Direct Print powered by KHS™ to market  (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)

Newsgrafik #30322

Innovation award for KHS  (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)

Newsgrafik #30307

KHS continues to grow in 2014  (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)

Newsgrafik #30008

KHS: much greater demand for PET consultancy  (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."

Newsgrafik #29848

KHS at NPE 2015 in Florida  (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)

Newsgrafik #29779

TÜV certificate for KHS glass filler  (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)

Newsgrafik #29496

Directly printed PET bottles in Nature MultiPacksTM win German Packaging Award 2014  (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)

Newsgrafik #29298

KHS compiles comprehensive innovation package  (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)

Newsgrafik #29159

The world's first company to promote the innovative KHS Plasmax technology to consumers  (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)

Newsgrafik #29143

KHS optimizes the Innoket 360 roll-fed labeler series  (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)

Newsgrafik #29046

KHS line heater for even more PET bottle material savings  (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)

Newsgrafik #28992

Light and right – pioneering position with user-friendly lightweighting  (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)

Newsgrafik #28970

Innopro Ecostab keeps its promises  (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)

Newsgrafik #28957

KHS Group: very good incoming orders and successful development in business year 2013  (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)

Newsgrafik #28934

KHS receives ISO 14001 and ISO 50001 certification  (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)

Newsgrafik #28764

Pioneering position with KHS  (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)

Newsgrafik #28724

KHS with new Innopouch K-400 pouching machine for the food and non-food industries  (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)

Newsgrafik #28623

Number two in two years  (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)

Newsgrafik #28615

Efes Ukraine invests in KHS turnkey glass line  (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)

Newsgrafik #28430

New Feedflow feed unit for reliable and gentle conveying of lightweight PET preforms  (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)


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.

Newsgrafik #28167

Amazing achievement  (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)

Newsgrafik #28160

KHS turnkey lines a major success factor  (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)

Newsgrafik #28148

Optimized KHS Innopack Kisters Primus SP shrink packer with many benefits  (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)

Newsgrafik #28116

Benchmark: new high-performance KHS palletizer with low-level pack feed  (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)

Newsgrafik #28068

Private brewery Moritz Fiege invests in the Innofill Glass DRS-ZMS  (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)

Newsgrafik #28034

Tradition meets innovation  (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)

Newsgrafik #28026

KHS wins 2014 German Design Award for ClearLine  (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)

Newsgrafik #28021

Premium packaging technology for premium spirits  (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)

Newsgrafik #28011

First-time investment in KHS stretch blow molding technology  (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)

Newsgrafik #27988

The Innofill Glass Micro – perfect for small and medium-sized breweries  (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)

Newsgrafik #27750

Even More Sustainability, Lower Operating Costs, and Greater Space Savings  (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)

Newsgrafik #27652

KHS Steps Up Involvement in Africa  (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)

Newsgrafik #27576

KHS PET event a great success  (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)


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)

Newsgrafik #26971

Austrian Brauerei Zipf upgrades bottle washer from 1991 with full conversion package  (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)

Newsgrafik #26758

Keg technology from the market leader   (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)

Newsgrafik #26751

Innovative generation of Innofill Glass Micro fillers now also for the wine & sparkling wine sector  (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)


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)

Newsgrafik #26467

KHS InnoPET Blomax Series IV awarded the   (Company news)


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)

Newsgrafik #26307

Khmer Brewery in Cambodia again invests in a KHS turnkey canning line  (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)

Newsgrafik #26296

For the bottling of still water under ultraclean conditions  (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)

Newsgrafik #26247

Gap now closed  (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)

Newsgrafik #26231

Completely satisfied - Hirsch Brauerei Honer all set for more sales success with new KHS turnkey lin  (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)

Newsgrafik #26143

Mark of distinction for KHS Innofill Glass filler platform  (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)


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)

Newsgrafik #26013


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)

Newsgrafik #25975

Petainer and Sovereign Beverage Company Announce Investment in UK Breweries  (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)

Newsgrafik #25941

Optimized KHS Innopack Kisters Basic Series with Plenty of Added Bonuses  (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)

Newsgrafik #25933

98% Market Share for Beer and 60% for Water  (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)


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)


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)


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)

Newsgrafik #25387

New generation of Innosept Asbofill ABF aseptic linear filling machines are a great success  (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)

Newsgrafik #25141

Innoket 360 S Labeling machine - Trend-setting roll-fed system with slim-line design  (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)

Newsgrafik #24251

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

Newsgrafik #23853

Certificate from TÜV SÜD  (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)

Newsgrafik #21421

KHS in-house exhibition with 100 participants a resounding success  (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)

Newsgrafik #21111

Innopro ECOStab Rings in New Era of Stabilizing Beer  (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)

Newsgrafik #20821

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


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)

Newsgrafik #15261

KHS Presents Innokeg Till CombiKeg Live for the First Time  (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)

Banco de datos puesta al día por la última vez: 04.08.2020 16:37 © 2004-2020, Birkner GmbH & Co. KG