08.495 KHS Journal 02_08 engl_US.qxd - KHS GmbH
08.495 KHS Journal 02_08 engl_US.qxd - KHS GmbH
08.495 KHS Journal 02_08 engl_US.qxd - KHS GmbH
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
<strong>KHS</strong><br />
VALUE ADDED BOTTLING<br />
TURNKEY PET LINES<br />
<strong>KHS</strong> Offers Customers Complete Competence<br />
2°20<strong>08</strong><br />
journal<br />
New Belgium Brewery:<br />
Premiere in the U.S.A<br />
Strong Partners<br />
Asahi Group: 27 Filling Systems from <strong>KHS</strong><br />
Beer for the World<br />
Coca-Cola Içecek<br />
Dry ACF for Coca-Cola<br />
Precise. Flexible. Future Proof.<br />
Perfect Pouchers<br />
English
editorial<br />
THE <strong>KHS</strong> PORTFOLIO IS COMPLETE:<br />
VALUE ADDED BOTTLING IS A STRONG PL<strong>US</strong>.<br />
Dear Readers,<br />
Earlier this year the media reported that Salzgitter AG, the majority shareholder of the <strong>KHS</strong> parent company Klöckner<br />
Werke AG with a share of around 86%, acquired SIG Beverages, a worldwide leading specialist for PET blow<br />
molding technology (slogan: value added bottling). Today I would like to tell you about the state of the cooperation<br />
and in particular about opportunities for <strong>KHS</strong>.<br />
Right from the beginning, it was clear that the merger provided the <strong>KHS</strong> Group with outstanding PET expertise<br />
that will enable <strong>KHS</strong> to offer complete systems from one source in the dynamically growing market for plastic<br />
bottle technology. This includes a transparent, uniform market presence. Accordingly, the individual companies<br />
have since been renamed to <strong>KHS</strong> Corpoplast (stretch blow molding technology), <strong>KHS</strong> Asbofill (aseptic filling of<br />
sensitive products), <strong>KHS</strong> Plasmax (barrier coating), and <strong>KHS</strong> Moldtec (mold production). At the present time,<br />
our teams are additionally coordinating their sales activities, laying the foundations for close technical cooperation<br />
and dealing with a wide range of other integration issues. This process is carried out in a cooperative and<br />
constructive manner. Although the focus is on joint advancement of the strengths of all companies involved,<br />
our customers will continue to have access to existing contacts and persons they know.<br />
A key factor is that <strong>KHS</strong> is now able to offer all customers – around whom ultimately everything revolves – complete<br />
solutions from one source, because the expertise gained in development, production, barrier coatings, and<br />
aseptic filling in the PET segment over three decades essentially completes the <strong>KHS</strong> portfolio. World-renowned<br />
<strong>KHS</strong> competence for filling and packaging meets unique competence in the field of PET. The Group is thus able<br />
to offer customers even more sophisticated, interface-free, environmentally and economically sustainable solutions<br />
over the entire product cycle of the machines. I am convinced that value added bottling is a strong plus<br />
for the future of <strong>KHS</strong> and will quickly make a positive contribution to the continuing success of the group.<br />
In conclusion, the results of the <strong>KHS</strong> Group for the previous financial year 2007 are certainly impressive: a significant<br />
increase in sales of 32.4% led to revenues of almost 1 billion euros, incoming orders exceeded the<br />
already successful previous year by a further 7.8%, and the operating profit reached around 39 million euros. In<br />
a word: 140 years after the company was established, <strong>KHS</strong> remains a solid and successful trusted partner.<br />
Yours truly,<br />
Valentin Reisgen,<br />
Chief Executive Officer of <strong>KHS</strong> AG<br />
» World-renowned <strong>KHS</strong> competence for filling and<br />
packaging meets unique competence in the field of PET. «
04<br />
07<br />
10<br />
14<br />
18<br />
22<br />
26<br />
30<br />
33<br />
36<br />
39<br />
42<br />
46<br />
48<br />
50<br />
53<br />
56<br />
59<br />
people+markets<br />
news<br />
Customers, Know-how, and Contacts<br />
Focus on:<br />
Value added bottling: Comprehensive PET expertise from a single source<br />
Turnkey PET Lines<br />
dossier<br />
Pouch filling and packing: <strong>KHS</strong> offers everything from one source<br />
Perfect Pouchers<br />
dialog+opinion<br />
Interview mit Dr. David Bosshart<br />
“Globalization Enters a New Phase”<br />
task+solution<br />
The Asahi Group now operating 27 filling systems from <strong>KHS</strong><br />
Beer for the World<br />
Coca-Cola Içecek relies on new technology<br />
Dry ACF for Coca-Cola<br />
Anton Hübner, provider of innovative health products,<br />
labels perfectly<br />
Stick-to-it-iveness<br />
Kumbok-Ju relies on soju – and <strong>KHS</strong><br />
Traditionally Progressive<br />
Karlsberg Brewery invests in highly flexible <strong>KHS</strong> system technology<br />
Made to Measure<br />
New Belgium Brewery in Colorado places trust in <strong>KHS</strong><br />
Strong Partners<br />
Kulmbacher Brewery: Focus on quality and environment<br />
The Beer Experts<br />
Brauerei Hacklberg combines tradition and innovation<br />
Firm Roots<br />
technology+innovation<br />
Innofill NRS: Worldwide new principle for bottling convenience drinks<br />
Focus on Wellness<br />
For non-alcoholic beverages: Now integrated hot-fill version for PET<br />
Hot Stuff<br />
Product line harmonization at <strong>KHS</strong>:<br />
Packaging technology for the future<br />
As Flexible as the Alphabet<br />
Technical terms in practice: Don’t be afraid of statistics (Part 1)<br />
Magic Numbers<br />
stopover<br />
Don’t miss the opportunity<br />
04<br />
10<br />
18<br />
39<br />
42<br />
48<br />
59<br />
contents ° 2°20<strong>08</strong> <strong>02</strong>*03
Left Logistics Day at TU Dortmund: Volker Till, Chief Technical Officer, <strong>KHS</strong> AG, announces the endowment of a professorship for filling and pack-<br />
aging processes. Right Discussion session: (from left) Volker Till, Dr. Volker Paetz (CEO ThyssenKrupp Materials International), Michael Brock-<br />
haus (CEO Rhenus AG), Norbert Przystupa (Managing Director of forty-five Personalberatung).<br />
<strong>KHS</strong> ENDOWS PROFESSORSHIP FOR FILLING AND PACKAGING PROCESSES AT TU DORTMUND<br />
OPPORTUNITIES FOR YOUNG TALENT<br />
“The purpose of endowing a professorship<br />
for filling and packaging processes at the<br />
Institute for Intralogistics and IT as a center<br />
for scientific research into technical<br />
logistics is to contribute toward promoting<br />
consistent basic research,” said <strong>KHS</strong><br />
CTO Volker Till at a press conference during<br />
the Logistics Day on 17 April 20<strong>08</strong> in<br />
Dortmund. The new <strong>KHS</strong> endowment for<br />
TU Dortmund, which will initially run for a<br />
five-year period, will focus on integrated<br />
networking of technology and IT in logistics<br />
processes.<br />
<strong>KHS</strong> sees this as a contribution to<br />
the expansion of logistics expertise at Dortmund,<br />
with the intention of engaging with<br />
key topics in research and education. Volker<br />
Till: “By working together on research projects<br />
relating to filling and production<br />
processes we intend to strengthen the<br />
robustness and performance of our products,<br />
speed up the formation of know-how,<br />
and promote specific project ideas.” Prof<br />
Michael ten Hompel, Chair for Conveyor<br />
and Warehouse Systems at TU Dortmund,<br />
Managing Director of the Fraunhofer Institute<br />
for Material Flow and Logistics IML at<br />
Dortmund, and founder of the new Institute,<br />
emphasizes, “<strong>KHS</strong> is contributing a<br />
wealth of expertise in filling and packaging<br />
engineering, process design and organization<br />
and logistics for modularly interlinked,<br />
integrated production systems.”<br />
This is an ideal basis for successful joint<br />
research and development projects.<br />
In this way, <strong>KHS</strong> promotes young talent by<br />
providing high-quality academic education<br />
while gaining access to bright graduates and<br />
scientists who research, study, and work at<br />
the new Institute as part of international<br />
activities. For Volker Till, student programs,<br />
dissertations, theses, site visits, and traineeships<br />
therefore represent important potential<br />
links: “The international outlook of the<br />
Institute offers scope for recruiting suitably<br />
qualified individuals into our team.”<br />
Praise for <strong>KHS</strong>: Professor Michael ten Hompel, TU Dortmund (second from left)
<strong>KHS</strong> DRY TECHNOLOGY AT GEHL FOODS, INC., U.S.A.<br />
FDA ISSUES LETTER OF NON-OBJECTION<br />
The U.S. Food and Drug Administration (FDA) who responsibilities<br />
include protecting the public health by assuring the safety of the<br />
nation’s food supply, has issued Gehl Foods, Inc., Germantown, WI,<br />
U.S.A., approval (letter of non-objection) for a high-performance<br />
ACF bottling machine from <strong>KHS</strong>. The technology of the Innofill<br />
ACF is based on a special aseptic filling system developed by <strong>KHS</strong><br />
that operates with hydrogen peroxide according to the principle<br />
of fully automatic dry sterilization and offers numerous production<br />
and cost benefits (see page 26).<br />
Gehl Foods, Inc. is a leading, widely diversified dairy facility<br />
in the U.S. that has pioneered in the production and packaging<br />
of shelf-stable dairy products and since 1970 has successfully<br />
relied on aseptic cold filling. This <strong>KHS</strong> line (600 8 – 14-oz. bottles<br />
per minute) increases the number of low acid product lines in<br />
operation at the company to a total of 16. The cutting-edge filler<br />
meets the growing demand for non-refrigerated dairy products and<br />
features a unique, re-sealable cap that avoids the foil seal method.<br />
John Gehl, CEO of Gehl Foods, charts the future direction of the<br />
company: “With the rising cost of refrigerated distribution, we are<br />
seeing even more desire for non-refrigerated products. Gehl’s plans<br />
to take advantage of that demand and remain the preferred leader<br />
in our industry.”<br />
<strong>KHS</strong> PROMOTES VLB BERLIN<br />
MINI PASTEURIZER FOR RESEARCH<br />
In May this year, the Research Institute for Brewing and Malting<br />
Technology, Berlin (VLB Berlin) put a test Innopas C pasteurizer<br />
into operation donated by <strong>KHS</strong>. This is an investment in the<br />
future for <strong>KHS</strong> and intensifies its cooperation with VLB regarding<br />
research and development in the field of PET pasteurization. The<br />
Berlin-based institute is involved in trend-setting research in this<br />
field. Because of the ever-increasing market demand for PET bottles<br />
for biologically sensitive beverages, the researchers are striving<br />
to optimize the temperature-time profile and develop bottles<br />
capable of withstanding the conditions prevailing in tunnel pasteurizers.<br />
This is very well possible with the test pasteurizer from<br />
<strong>KHS</strong> which is able to reproduce the complete pasteurization process<br />
on a footprint of only about two square meters while providing<br />
the same flexible functionality offered by its big bother of the<br />
Innopas C series.<br />
people+markets ° news 04*05<br />
Close ties with <strong>KHS</strong> since 1958: Jörg Wallmüller (center) with <strong>KHS</strong> CEO<br />
Valentin Reisgen (right) and Helmut Weber, Chairman of the Joint Works Council.<br />
<strong>KHS</strong> IN-HO<strong>US</strong>E<br />
JÖRG WALLMÜLLER 50 YEARS AT <strong>KHS</strong><br />
Antoine de Saint-Exupéry believed “Being true to others means<br />
being true to yourself,” long before Jörg Wallmüller joined <strong>KHS</strong>.<br />
Wallmüller, now a sales engineer in the Central Logistics / Purchasing<br />
Dept., began his training as a machinist on April 1, 1958 with<br />
a company to which he has remained loyal for 50 years. On completion<br />
of his training, Jörg Wallmüller (born in 1943) worked<br />
first in the chain construction final assembly department and<br />
then the packer and palletizer construction departments. In 1965,<br />
he attended a private engineering night school for three years in<br />
addition to his full-time job. Now a construction technician, he<br />
was then promoted to a position as a technical employee in 1968<br />
and worked as an administrative assistant in the packer spare parts<br />
department. Wallmüller, who has been working as a sales engineer<br />
with a wide range of tasks since 1973 is respected and well-liked<br />
by both colleagues and customers. The Executive Board and the<br />
employees of <strong>KHS</strong> AG thank Jörg Wallmüller for his commendable<br />
commitment to his <strong>KHS</strong> over past half-century.<br />
WWW.<strong>KHS</strong>.COM/INDIA<br />
SPECIAL WEBSITE FOR INDIA<br />
Because customers need to be well informed at the regional level<br />
as well, the <strong>KHS</strong> team has developed a special website for the booming<br />
subcontinent of India after completing a special website for<br />
the U.S. This website provides information on the incorporation<br />
of the country into the company group as well as special knowhow<br />
in India. Including among other things information and<br />
facts on the location, points of contact, services, customer events,<br />
trade fairs, and news. For <strong>KHS</strong>, the Indian site Ahmedabad is an<br />
important strategic location for other Asian markets as well. A new<br />
plant was recently opened in Ahmedabad in 2007 according to <strong>KHS</strong>’<br />
globally applicable quality standards. Look for the India website<br />
under Quicklinks on the <strong>KHS</strong> homepage or click on<br />
www.khs.com/india.
FLASHBACK: <strong>KHS</strong> AT THE INTERPACK 20<strong>08</strong><br />
ALL-ROUNDER FOR POUCHES<br />
<strong>KHS</strong> has just recently introduced a far-reaching innovation to the<br />
market for pouches. By integrating ExpertPack into this sector,<br />
<strong>KHS</strong> has now become a complete and turnkey supplier now offering<br />
a product line that includes everything from form / fill / seal<br />
machines, to pouch packaging systems, up to and including a cartoning<br />
and palletizing program.<br />
As the many visitors to <strong>KHS</strong>’ booth saw for themselves at<br />
this year’s Interpack in Düsseldorf (2744 exhibitors, 179,000 visitors),<br />
the focus was on innovative technical solutions for processing<br />
pouches, a new version of the modular packer for disposable<br />
packaging, and the wrap-around packer especially designed<br />
for the entry and medium capacity ranges. In brief,<br />
The new Innopouch K series poucher combines the functions<br />
of manufacturing pouches and filling them with product in<br />
one work step. Special features: The system processes either flat<br />
rollstock or fills pre-made fin-seal or stand-up pouches in a wide<br />
range of sizes at speeds of up to 105 packs per minute in single<br />
mode. The horizontal motion mode of operation ensures maximum<br />
leakproofness of the fin seals even for the most sensitive of products<br />
(see page 14). What’s more, the innovative <strong>KHS</strong> packer concept<br />
provides exceptionally gentle pouch handling coupled with<br />
plenty of flexibility.<br />
With its Innopack Kisters TSP tray shrink packer, <strong>KHS</strong><br />
presented a completely redesigned, and in many aspects further<br />
developed, packaging machine in the modular product series featuring<br />
outputs ranging from 35 to 135 cycles per minute. Harmonizing<br />
the product range makes future conversions even easier<br />
and faster (see page 53).<br />
Lastly, <strong>KHS</strong> presented a new generation of shrink tunnels<br />
that in addition to electric operation can also be heated with<br />
gas, which is not only more economical but also sensible from an<br />
ecological standpoint. Depending on the installation location,<br />
users can save up to 50 percent on energy costs and reduce the<br />
CO2 output by up to 60 percent (see <strong>KHS</strong> journal 1/<strong>08</strong>).<br />
The new Innopack Kisters WP 030 wrap-around packer<br />
is designed especially for the entry to medium output ranges in the<br />
food, beverage, and non-food sectors. Special features include outputs<br />
of up to 30 cycles per minute optionally for wrap-around or<br />
tray packaging. The operator friendly machine flexibly processes<br />
cans, jars, glass and PET bottles, and pre-wrapped packaging.<br />
A great deal of interest in innovative packing technology was shown by<br />
the visitors to the <strong>KHS</strong> exhibition booth.<br />
CORNERSTONE LAID<br />
NEW ASSEMBLY SHOP AT <strong>KHS</strong> WORMS<br />
On June 6, 20<strong>08</strong>, <strong>KHS</strong> COO Dr. Ing. Johann Grabenweger<br />
together with Lord Mayor Michael Kissel and Jens Guth, member<br />
of Rhineland Palatinate’s parliament, laid the cornerstone<br />
for a new assembly shop at <strong>KHS</strong>’ plant in Worms. The<br />
shop is to be equipped with a 20-ton crane rail, will occupy<br />
and area of nearly 2500 square meters, reach an impressive<br />
height of 14.4 meters, and will be used to manufacture packing<br />
and palletizing machines. <strong>KHS</strong>’ competence center for<br />
packing and palletizing technology is thus making a lasting<br />
investment in the future. Dr. Ing. Johann Grabenweger, “Our<br />
intention is to achieve a breakthrough and increase our efforts<br />
in the food and non-food sectors in addition to the beverage<br />
industry.” Plant manager Peter Müller sees substantial<br />
potential worldwide particularly in the area of palletizing.<br />
“By expanding this plant, we want to be well prepared. And<br />
that includes providing 20 new jobs.” The assembly shop is<br />
planned to go into operation by the end of August. Incidentally,<br />
the stainless steel capsule sealed in the cornerstone<br />
during the ceremonies was made in <strong>KHS</strong>’ apprentices’ training<br />
shop. Tradition meets technology.<br />
Laying the cornerstone (from left to right): Michael Kissel,<br />
Lord Mayor of the city of Worms, Dr. Ing. Johann Grabenweger,<br />
Chief Operations Officer <strong>KHS</strong> AG, and Jens Guth, member of<br />
the Rhineland Palatinate state parliament.
<strong>KHS</strong> AROUND THE WORLD<br />
C<strong>US</strong>TOMERS, KNOW-HOW, AND CONTACTS<br />
<strong>KHS</strong> has been represented in world markets by its engineering and the proficiency of its employees for<br />
140 years. The company stands for absolute customer-orientation, problem-solving competence of its<br />
high-tech experts, and the know-how of a consulting staff that contributes expertise on economic<br />
issues. The <strong>KHS</strong> team demonstrates this worldwide day after day.<br />
COCA-COLA IÇECEK, TURKEY<br />
NEW LOCATION – NEW LINE<br />
The order placed by the renowned bottler Coca-Cola Içecek (CCI) for its new<br />
mega plant in Elazig in southeast Turkey was bitterly contested. A number<br />
of suppliers wanted to install the first line at this site. <strong>KHS</strong>, who has had<br />
good business relations with CCI for many years, was awarded the contract.<br />
For this high-performance system as well, the bottler once again placed its<br />
confidence in the perfect project management and robust machines from<br />
<strong>KHS</strong>. The line fills all five bottle types including 1.0-, 2.0-, and 2.5-liter<br />
contour, straight wall, and Fanta Splash bottles and is optionally capable of<br />
processing the 0.45-milliliter type of packaging in the future as well. The<br />
line is comprised of:<br />
* A BLOWMAX 20 blow molder from <strong>KHS</strong> Corpoplast that feeds bottles to the<br />
filler inline directly over an air conveyor.<br />
* An Innofill DRV 162 VF/N filler (also suitable for non-carbonated products)<br />
equipped with a sanitary room enclosure complete with HEPA filters that<br />
has been designed with adequate space to accommodate an ionized air<br />
rinser later.<br />
* The two-lane dry area – comprised of two Innopack Kisters SP shrink<br />
packers, two robot grouping stations, two palletizers, and two pallet stretch<br />
wrappers – includes a compensating distributor so that production can be<br />
run from packer 1 to palletizer 2 and vice versa.<br />
BOSTON BEER COMPANY, PENNSYLVANIA, U.S.A<br />
HIGH-TECH MEETS THE TRADITIONAL<br />
Boston Beer, the largest and leading brewery for craft-brewed beer in the<br />
United States, is receiving from <strong>KHS</strong> a complete new 280 keg-per-hour Till<br />
TRANSOMAT 5/1 keg racking line for its plant in Miscellaneous Allentown, Pennsylvania.<br />
This turnkey line includes robots for palletizing and depalletizing.<br />
The Allentown brewery took over Boston Beer from Diageo to position this<br />
brand it as its flagship for traditional brew.<br />
people+markets ° news<br />
ELDE CANNED FOODS, ZACHOW<br />
QUALITY OF SERVICE ALSO<br />
COMPELLING<br />
For the first time, ELDE Konserven in Brandenburg’s<br />
Zachow near Parchim has decided in favor of <strong>KHS</strong> by<br />
ordering two rotary Innoket ROLAND 8/4 labeling<br />
machines, each designed for an output of 6,000 jars<br />
per hour. The more than 100-year-old still active producer<br />
of high-quality canned foods is convinced by<br />
the high quality of <strong>KHS</strong> machines and the comprehensive<br />
service provided by <strong>KHS</strong> that also includes unproblematic<br />
spare part procurement. Here, “<strong>KHS</strong> has the<br />
leading edge.” With a workforce of currently 170 employees,<br />
the company produces approx. 30,000 tons of raw<br />
goods on 4 production lines operating on a floor space<br />
of 7,000 square meters. Forty percent of ELDE Konserven’s<br />
sales are realized in other European countries.<br />
06*07
HOCHWALD, THALFANG, GERMANY<br />
PACKER FOR “BÄRENMARKE”<br />
Hochwald Nahrungsmittel-Werke is receiving an Innopack Kisters<br />
TSP 050 tray shrink-packer for its plant in Weiding (Mühldorf) to<br />
process cans and jars of “Bärenmarke”, its internationally wellknown<br />
brand of condensed milk. The system processes all variations<br />
of the variety of packaging at an output of 500 cans per minute<br />
(30,000 per hour) on one or two lanes depending on the formation<br />
and output. This is Hochwald’s first decision in favor of packing<br />
machines from <strong>KHS</strong>. The extremely high level of flexibility and<br />
the forward-looking technological concept of the system were the<br />
decisive factors. Hochwald saw for itself the great potential of<br />
the packing machine on inspection tours and at the open house<br />
exhibition celebrating the 50th anniversary of <strong>KHS</strong>’ Kisters plant<br />
in Kleve.<br />
CROWN BEVERAGES, UGANDA<br />
PREMIERE IN KAMPALA<br />
The internationally renown Pepsi franchise bottler CROWN BEVER-<br />
AGES LIMITED of Kampala, Uganda has made a first-ever decision<br />
in favor of a <strong>KHS</strong> turnkey bottling line. The line is designed to fill<br />
0.3-liter refillable glass bottles with Pepsi products and tonic water<br />
at 40,000 bph. The components: Innopack PPZ crater / decrater<br />
(24-bottle plastic crates), Innoclean KW crate washer, Innoclean<br />
DM double-end bottle washer (with extra long treatment and submersion<br />
periods), Innopro CMX Paramix, Innofill DMG VF filling system,<br />
fill level checking, and manual palletizing.<br />
COCA-COLA ENTERPRISES, BELGIUM<br />
ROBOT CREATES FLEXIBILITY<br />
<strong>KHS</strong> is installing an Innopal RK 6 palletizer with robot<br />
grouping for crates at the Ghent plant of Coca-Cola<br />
Enterprises, Belgium. After the bottles are sorted,<br />
the system conveys the production bottles to the filling<br />
system and then segregates the filled bottles (three<br />
types) and packs them in crates. The crates are fed over<br />
three crate conveyors to the <strong>KHS</strong> palletizer with robot<br />
grouping where the crates are put into formation and<br />
loaded on a separate pallet. This ensures maximum<br />
flexibility with the advantage that complete layers of<br />
crates can be palletized on three separate pallets and<br />
not palletized crate by crate. As an articulated robot,<br />
the Innopal RK provides a large 360° working radius on<br />
a minimum footprint, has no dead spots, and thus allows<br />
a high degree of freedom when planning conveying system<br />
projects.
NORTHERN BREWERIES, SABMILLER, ZAMBIA<br />
42,000-BPH REFILLABLE GLASS LINE<br />
For the first time, Northern Breweries (1995) PLC in Ndola, Zambia, <strong>KHS</strong>’ longstanding<br />
business associate is taking delivery of a complete <strong>KHS</strong> refillable<br />
glass bottle line for carbonated beverages. The company is a member of the<br />
SABMiller Group. The line processes 0.3-liter (crown corks) and 1.0-liter bottles<br />
(screw-on caps) at 42,000 and 21,000 bottles per hour, respectively. The 0.3liter<br />
bottles are packed in twenty-four bottle crates while twelve-bottle crates<br />
are used for 1.0-liter bottles. The line is equipped with automatic palletizing and<br />
depalletizing, a crater and decrater, a bottle washer, a crate washer, an Innofill<br />
DPG VF filler, and an Innopro CMX Paramix.<br />
KOMPANIA PIWOWARSKA, POLAND<br />
ALL GOOD THINGS COME IN THREES<br />
<strong>KHS</strong> is now delivering the third 100,000-cph canning line to the well-known<br />
Kompania Piwowarska brewery group in Poznan, Poland (another 50,000-cph<br />
line is also operating successfully). The line ordered is designed to process 0.5liter<br />
cans. The company is a subsidiary of SABMiller and with an output of approx.<br />
14 million hectoliters (2007), is the leader of the Polish market (breweries: Browar<br />
Dojidy, Lech Browary Wilkopolski, and Tyskie Browary Ksiazece). By sales volume,<br />
the key brand Tyskie is one of Europe’s top ten best selling brands of beer.<br />
people+markets ° news<br />
DEL MONTE FOODS, PLYMOUTH, INDIANA, U.S.A.<br />
COMPLETE CONVEYING SYSTEM<br />
<strong>KHS</strong> has installed a complete conveying system at the<br />
headquarters of world famous and heritage-rich Del<br />
Monte Foods in Plymouth, Indiana. After the successful<br />
startup of the system, Del Monte Manager John<br />
Matthews praised the installation as the best ever in<br />
his 30 years of working for the company.<br />
CARLSBERG, DENMARK<br />
KEG LINE FOR TUBORG BEER<br />
Carlsberg Danmark AS in Fredericia has ordered a complete,<br />
310 keg-per-hour turnkey keg line for Tuborg<br />
Bryggerierne.<br />
NAFCA, LÜNEBURG, GERMANY<br />
WHERE QUALITY PREVAILS<br />
Lüneburg-based Nafca <strong>GmbH</strong>, a company committed<br />
to offering only high quality products has ordered a<br />
rotary Innoket ROLAND 10 H labeling machine (10,000<br />
bottles/hr) and an Innoket VARIANT 1 labeler designed<br />
for an output of 6,000 bottles per hour. The top quality<br />
of <strong>KHS</strong> products was the reason for the company’s<br />
first-time decision in favor of <strong>KHS</strong>.<br />
UNILEVER CR, CZECH REPUBLIC<br />
PALLETIZING TECHNOLOGY AT ITS FINEST<br />
Unilever CR located in the Czech town of Nelahozeves is expanding its<br />
previously installed <strong>KHS</strong> lines by adding cutting-edge palletizing technology.<br />
The machines in detail: one Innoline pack conveyor, Innoline<br />
pallet conveyor, Innopal handling robot each, and two Innopal LH<br />
palletizers, each with a capacity of maximum 1500 packs per minute.<br />
Unilever in the Czech Republic thus relies for the first time on palletizing technology<br />
from <strong>KHS</strong> in addition to the simple as well as economical technology of the new LH<br />
palletizer. Both palletizers are used for the Knorr wellness product “VIE”. An Innopal<br />
handling robot supplies both palletizers with the necessary cardboard slip-sheets.<br />
With this solution, Czech Unilever is cutting the cost of palletizing significantly.<br />
<strong>08</strong>*09
Value added bottling: Comprehensive PET expertise from a single source<br />
Turnkey PET Lines<br />
A valuable addition to Klöckner-Werke AG took place on April 2, 20<strong>08</strong>:<br />
The <strong>KHS</strong> Group, together with the four former SIG Beverages companies, have<br />
now combined their complementing PET expertise under the slogan<br />
“value added bottling” and now comprise the field of packaging solutions.<br />
<strong>KHS</strong> customers will benefit from this newly acquired PET knowledge<br />
by way of an attractive offering: Turnkey PET lines<br />
The companies of the former Beverages Division – Corpoplast,<br />
Plasmax, Asbofill, and Moldtec – are known<br />
around the world for their many years of proficiency<br />
relating to all aspects of high-quality plastic bottle solutions.<br />
Their comprehensive service package, Bottles &<br />
Shapes, takes into account all aspects of a complete<br />
bottle development – from the first design proposals<br />
to industrial production, while complying with the<br />
defined specifications. Corpoplast manufactures stateof-the-art<br />
stretch blow molding machines, Plasmax is<br />
a specialist for barrier coatings, and Asbofill supplies<br />
linear aseptic filling technology.<br />
These companies have long since not just seen<br />
themselves as machine builders, but have been very successfully<br />
active as modern service providers for PET packaging<br />
solutions. All individual packages, like the interplay<br />
under the “value added bottling” promise, have a<br />
single objective: calculable added value coupled with<br />
maximum availability and precise production resulting<br />
in minimum overall operating costs for the customer.<br />
BOTTLES & SHAPES: OVERALL PRODUCTION<br />
PROCESS IN FOC<strong>US</strong><br />
What characteristics must a bottle have in order to<br />
provide optimum protection for the product, to be able<br />
to be filled safely during production and, at the same<br />
time, effectively assist its marketing? The answer to<br />
this is given by the Bottles & Shapes service product.<br />
A brief summary of the core philosophy:<br />
* As early as the bottle design stage, bottle designers,<br />
PET experts, and line specialists take into<br />
account the entire process that the bottle goes<br />
through on its way to the point of sale.<br />
* Even the most sophisticated bottle design must<br />
result in a lightweight and at the same time stable<br />
bottle, which can be produced, filled, labeled, and<br />
transported efficiently.<br />
* The PET specialists take into account all influencinfactors:<br />
– At what points can easily less material be used<br />
without affecting the stability?<br />
focus °<br />
10*11
CORPOPLAST: Precision stretch blow technology with maxi-<br />
mum availability and minimum energy consumption.<br />
– How can the stretchability of the PET material be<br />
optimally utilized in order to decrease heating<br />
energy and air consumption?<br />
– How do the bottles behave during filling, on conveying<br />
systems, and on pallets?<br />
When all aspects have been taken into account, the customer<br />
is presented with an optimum bottle tailored to<br />
BOTTLES & SHAPES: Lightweight<br />
packaging solutions for plastic bottles with<br />
perfectly matched characteristics.<br />
PLASMAX: Wafer-thin, crystal clear barrier to<br />
protect sensitive products.<br />
his requirements. High-precision blow molds are developed<br />
and manufactured in parallel with the bottle design.<br />
Because of the high demands on perfection and availability,<br />
the molds are made by Moldtec in Essen.<br />
CORPOPLAST: LIGHT WEIGHTING AND PRECISION<br />
PRODUCTION<br />
An example of the Bottles & Shapes approach: In order<br />
to keep the overall operating costs as low as possible,<br />
cost-cutting measures include minimizing the use of<br />
materials. In times of skyrocketing oil prices and intensive<br />
competition, one thing is becoming more and more<br />
important especially in the water sector: Light weighting<br />
– reducing the bottle weight. When manufacturing<br />
100 million bottles, only one gram less weight leads<br />
to a saving of 120,000 euros in material costs alone.<br />
At the same time, the bottles must continue to<br />
be stable enough to enable customers to produce and<br />
transport them in a continuously repeatable process<br />
with maximum efficiency. Finally, the optimized plastic<br />
containers are manufactured on the standardized<br />
BLOMAX Series III modular high-speed blow molding<br />
machines from PET pioneer Corpoplast. These machines<br />
mean optimum process reliability, maximum availability,<br />
precise production, and minimum energy and spare<br />
parts consumption.<br />
PLASMAX: LIGHTWEIGHT AND CRYSTAL CLEAR<br />
FOR OPTIMUM PRODUCT PROTECTION<br />
Plasmax provides a special barrier solution for bottling<br />
in plastic bottles for the complete range of sensitive<br />
products including fruit juices, beer, and wine.<br />
For optimum shelf life and quality of these products,<br />
Plasmax has developed a unique process that coats
ASBOFILL: Innovative filling systems for<br />
sensitive products – linear, aseptic, flexible.<br />
the inside of the PET bottle with a crystal clear, pliable,<br />
and completely inert layer of silicon oxide (SiOx).<br />
This wafer-thin PLASMAX coating gives the lightweight<br />
plastic bottle the barrier characteristics of glass that<br />
protect the contents against oxygen pick-up – just like<br />
a glass bottle. The PLASMAX coating protects the product<br />
against CO 2 loss, a decisive criterion particularly in<br />
the case of small containers. An additional plus is that,<br />
unlike alternative barriers such as multi-layer or blends,<br />
PLASMAX-coated bottles are 100 percent recyclable.<br />
This reduces preparation costs and protects the environment.<br />
ASBOFILL: INTEGRAL ASEPTIC ZONE FOR MAXIMUM<br />
SAFETY WITHIN A MINIMUM AMOUNT OF SPACE<br />
Asbofill completes the value-added bottling chain with<br />
a reliable, aseptic filling method for microbiologically<br />
sensitive non-carbonated products. The ABF 610 and<br />
ABF 710 linear aseptic fillers from Asbofill provide an<br />
absolutely safe filling process for low and high acid<br />
products such as fruit juices, liquid dairy products,<br />
and neutraceuticals while taking up a minimum amount<br />
of space. The compact, integral aseptic zone of the<br />
filler with only 0.9 cubic meters not only increases the<br />
aseptic safety but at the same time also cuts investment<br />
and operating costs. In addition, a non-contact filling<br />
process provides increased protection.<br />
SYNERGIES BRING ADVANTAGES FOR C<strong>US</strong>TOMERS<br />
The recently acquired PET expertise now makes it possible<br />
for <strong>KHS</strong> to offer PET lines as turnkey projects for<br />
the first time. In doing so, customers benefit not only<br />
from machine and conveying know-how, but also from<br />
a plastic bottle that is adapted and designed to suit the<br />
• WEBSITE www.valueaddedbottling.de<br />
focus ° Value added bottling<br />
requirements of their lines, whether it be for high-speed<br />
rotary fillers or linear, aseptic filling systems. What is<br />
more, the combined expertise will enable new projects<br />
to be implemented even more quickly in the future. The<br />
experts in the company group are working at full speed<br />
on the development of monoblock stretch-blow bottling<br />
lines. Two ongoing projects are scheduled for<br />
installation this fall.<br />
The result: Together with the “value added bottling”<br />
experts Corpoplast, Plasmax, Asbofill, and Moldtec,<br />
<strong>KHS</strong> is the ideal PET turnkey partner for the beverage<br />
industry as well as the food and non-food sectors. In<br />
the future, the “value added bottling” promise will supplement<br />
the <strong>KHS</strong> motto “Filling and Packaging – Worldwide”<br />
for any type of PET line – from the first bottle<br />
design idea to the ready-to-deliver product range coupled<br />
with minimum operating costs.<br />
Matthias Damm, Marketing & Communications, <strong>KHS</strong> Corpoplast<br />
fi<br />
INFOBOX<br />
• CONTACT<br />
Matthias Damm, Marketing & Communications,<br />
<strong>KHS</strong> Corpoplast, Hamburg<br />
Tel: +49/40/679 07 350<br />
E-mail: matthias.damm@khs.com<br />
12*13
Pouch filling and packing: <strong>KHS</strong> offers everything from one source<br />
Perfect Pouchers<br />
The pouch boom is continuing unabated. With the<br />
new Innopack CMP packaging machine and the proven<br />
Innopouch K pouching machine, <strong>KHS</strong> now offers all<br />
sectors a complete range for a widest variety of pouch<br />
types. The modes of operation of the systems are<br />
consistently practice-oriented: precisely, flexibly,<br />
and with an eye to the future.<br />
There are trends that take time to become established worldwide.<br />
And there are trends that virtually zip around the world. Above<br />
all, the flat pouch is the current trend in the filling and packaging<br />
industry. Or, more precisely, the trend toward fin-seal bags,<br />
stand-up bags (also referred to as Doypacks or pouches), blockbottom<br />
bags, or flow packs. The food and beverage industries as<br />
well as the non-food industry are selling more and more products<br />
to the customer in this kind of pouch. Today, anyone Googling for<br />
the term Doypack will find around 128,000 entries – just two<br />
years ago, there would have been only 88,600 hits.<br />
Experts are accordingly forecasting worldwide growth rates<br />
for the popular pouch of more than ten percent per year. Because<br />
when attractively and eye-catchingly printed, they initially signal<br />
added value for the product they contain. Furthermore, they perfectly<br />
suit the lifestyle of the customer: as single or family pack<br />
and with convenience attributes such as special sealing systems<br />
and maximum ease of opening. And lastly, pouches take up hardly<br />
any more space than that occupied by the filled product itself.<br />
Thousands of companies are therefore now saying that the pouch<br />
is a must, instead of the classical can, bottle, or carton.<br />
With the newly designed Innopack CMP pouching machine<br />
and the group’s existing cardboard box and palletizing know-how<br />
complementing the successful Innopouch K poucher in the marketplace<br />
(see Page 16), <strong>KHS</strong> now offers a complete and comprehensive<br />
range.<br />
PRECISE. FLEXIBLE. FUTURE PROOF.
Top Cartridges: In the closed conveying position and in the open<br />
loading position. The fins suspended between the pouches compensate<br />
for different pouch thicknesses. Bottom Innopack CMP:<br />
View of the machine outfeed. Display boxes packed with stand-up<br />
pouches leaving the packer.<br />
dossier °<br />
INNOPACK CMP: WIDE CAPACITY RANGE<br />
The Innopack CMP processes 60 to 250 pouches per minute depending<br />
on type and design. Pouch sizes may range from 90 mm wide<br />
and 100 mm high up to 200 mm wide and 250 mm high. Other<br />
package sizes can be processed without difficulty. Cartons can be<br />
filled with pouches at a maximum output of up to 30 cartons per<br />
minute.<br />
INNOPACK CMP: HIGH FLEXIBILITY<br />
Maximum flexibility is important for the pouch type of packaging.<br />
<strong>KHS</strong> is therefore prepared for all eventualities. Regardless if pouches<br />
arrive horizontally with the wide side first, horizontally with the<br />
narrow side first, or upright – the system responds accordingly. If<br />
pouches enter the packaging system with the narrow side first,<br />
they are turned 90 degrees by a corner turntable, and those that<br />
are not exactly in line are perfectly re-aligned.<br />
Horizontal pouch packs pass to an uprighting module with<br />
the wide side first. The machine handles packaging and product<br />
extremely gently. What happens, however, if the contents shift,<br />
as in the case of powdery and chunky products? The system then<br />
equalizes the pouch contents in an upstream vibration segment<br />
to save space later in the carton. This is all done with minimal<br />
pressure without harming the product or damaging the pouches.<br />
INNOPACK CMP: EXACT POSITIONING<br />
Whether powdery, chunky, pasty, or liquid products, all pouches<br />
pass horizontally conveyed by two vertical parallel belts (feed unit)<br />
directly into the packer designed in the form of a carousel. The<br />
belt system not only conveys less sensitive liquid and pasty products<br />
accurately into the cartridges provided, but at the same time<br />
also equalizes the pouch contents. The feed unit is always configured<br />
exactly to suit the type of pouch to be processed. Spindles<br />
are used to make adjustments for product and package<br />
changeover.<br />
The system now pushes the pouches into cartridges that<br />
are comprised of several vertically arranged plates. While the outer<br />
14*15<br />
PRECISE. FLEXIBLE. FUTURE PROOF.
2<br />
POUCH FILLING: ONLY WITH INNOPOUCH<br />
More than 55 years ago, <strong>KHS</strong> already recognized what the market was demanding more than ever and has already installed more<br />
than 3,900 horizontal form / fill / seal machines. With the Innopouch K model range, a generation of machines entered the world<br />
market that combines the experience of the company with the specifications of big-name multinational customers. It was the users<br />
and operators of such machines that defined the requirement specifications for the development of these machines. In a nutshell:<br />
<strong>KHS</strong> answers all issues relating to filling with the Innopouch K<br />
• liquid products such as soups, sauces, ketchup, and juices,<br />
• pasty items such as marzipan or puree, and<br />
• dry products, ranging from instant soups to baking powder<br />
COMPACT PRESENTATION: THE SIX HIGHLIGHTS<br />
The Innopouch K product range processes either from flat rollstock<br />
or filled pre-made pouches. The operator can quickly switch to the<br />
appropriate mode. Here the distinguishing characteristics of the<br />
machine in brief:<br />
1. Broad spectrum. Fin-seal and stand-up pouches 80 to 350<br />
mm long and 80 to 360 mm wide / 105 pouches per minute in<br />
single mode.<br />
2. Exceptionally well sealed. The new pouch forming method<br />
enables the sealing pressure to be applied linearly, while the servo<br />
motor direct drive enables processing of both very thin and very<br />
thick wrapping materials. The sealing parameters are displayed<br />
reproducibly on the operator panel and are monitored by the control<br />
system. A form / fill / seal machine, which is also suitable<br />
for producing so-called retort pouches, is available for the first<br />
time. These are pouches made of materials that allow them to<br />
be sterilized after filling at temperatures ranging from 121 to<br />
128 degrees Celsius. The sealed seams meet maximum requirements<br />
for leakproofness. This is particularly important when filling<br />
sensitive liquid products.<br />
3. Modular concept. Individual machine design according to the<br />
processed product / Fin-seal and stand-up pouches made from<br />
all common hot-sealable packaging materials / Up to four side-<br />
Left Horizontally conveyed pouches are continuously uprighted before entering the<br />
packing cartridges. Top Pouches held in cassettes, synchronized over an open display<br />
box, and placed in the box.<br />
by-side metering stations as standard equipment / Optional feature:<br />
sealing of pouring spouts and adapters and top seam sealing<br />
with ultrasound. Modularity also means that the machine produces<br />
and fills pouches both from the flat rollstock and also, after<br />
changeover, processes pre-made pouches fed from a magazine.<br />
4. Reliable control. Double gripper system receives the pouches<br />
/ They remain in a linear arrangement up to the pouch outfeed<br />
station / Reliable control at all times.<br />
5. Flexible filling / dosing. Up to four dosing stations can be connected<br />
in series as standard / Dosing and filling are both volumetric<br />
and gravimetric. Servo motor-driven filling nozzles or<br />
hoppers increase the standard machine output capacity by up to<br />
1.4 times, depending of course on the characteristics of the product<br />
to be filled and the rollstock.<br />
6. Fast cleaning. No corners or crevices of any kind underneath<br />
the gripper systems / Extremely short cleaning times.<br />
THE MARKET GETS WHAT IT NEEDS<br />
All in all, the <strong>KHS</strong> Innopouch K poucher is a technology that the<br />
market demands. In short: The modular design allows maximum<br />
flexibility and individuality complemented by maximum production<br />
reliability with consistent clean design in addition to maximum<br />
convenience in operation, cleaning, and changeover.<br />
RECISE. FLEXIBLE. FUTURE PROOF. PRECISE. FLEXIBLE. FUTURE PR
dossier ° Pouch filling and packing: <strong>KHS</strong> offers everything from one source 16*17<br />
Indexed into the packer: Pre-made<br />
display boxes still open at the top.<br />
plates are stationary, the adjustable inner plates can be exactly<br />
matched to the packs to be processed in each instance. When all<br />
cartridge compartments have been filled, the cartridge is conveyed<br />
to the carton packer by a friction drive.<br />
At the carton station, the carton blanks are erected, glued,<br />
and indexed simultaneously. Servo technology positions the cartridge<br />
directly above the ready and waiting carton. The cartridge<br />
then moves parallel to the continuously forward moving carton into<br />
which it is lowered and then retracted. The upright positions of<br />
the equalized pouches save space and improves the display effect<br />
versus horizontally packed pouches.<br />
INNOPACK CMP: MIXED PACKS POSSIBLE<br />
The trade is increasingly demanding mixed packs. The <strong>KHS</strong> packer<br />
is prepared for this eventuality. The system feeds two or even three<br />
pouches per compartment into appropriately designed cartridges.<br />
A plate distributor located ahead of the corner turntable or uprighting<br />
module ensures that the various types of pouch pass to the<br />
machine in the required order. Important: When processing mixed<br />
packaging, the pouches are fed from a storage or buffer area to<br />
ensure that the packer is continuously supplied with the correct<br />
type of pouch in each case. Faulty pouches are very simply ejected<br />
out of the system by a flap mechanism contained in the cartridge<br />
conveyor.<br />
INNOPACK CMP: HIGHLY FUTURE-PROOF<br />
Not only mixed packs point to a flexible future. The packing system<br />
can also be adapted to new requirements at any time without<br />
difficulty. Case 1: As long as there is no change in the number of<br />
pouches in a carton, the plates in the cartridges can be adjusted<br />
by means of spindle to adapt taller, wider, heavier, or lighter weight<br />
pouches. A spindle adjustment is also used to adjust the infeed<br />
area. Only the carton erector needs a new set of format parts. Case<br />
2: If the number of pouches to be packed in each carton changes,<br />
a new format set is implemented simply by changing cartridges. A<br />
quick-release lock makes for rapid removal and installation. If an<br />
increase in capacity is planned, additional cartridges can be incorporated<br />
into the system. Each new format is stored in the controller<br />
by adapting the software. Thus, when changing formats,<br />
all that is necessary is to select the appropriate format on the display<br />
screen.<br />
INNOPACK CMP: MODULAR DESIGN<br />
The continuously rotating carousel accommodates up to seven<br />
cartridges. The modular system design is particularly suitable for<br />
those customers who are just starting with pouches and are not<br />
yet able to foresee their success. The slogan: Start with a few cartridges<br />
and simply upgrade with increasing success. If all available<br />
cartridges are exhausted, the modular concept enables users to<br />
integrate additional stand-alone carousels into the pouching system.<br />
INNOPACK CMP: PERFECTLY INTEGRATED<br />
The Innopack CMP is directly coupled to the <strong>KHS</strong> machinery installed<br />
upstream and downstream. There are no interface problems – the<br />
speed is controlled automatically. Not least because of its small<br />
footprint, the system can be perfectly integrated into existing technical<br />
solutions. In short, a technical solution that meets the market<br />
demand.<br />
Thomas Matheyka, Product Management Pouching Machines, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.khs.com<br />
• CONTACT<br />
Thomas Matheyka, Product Management,<br />
Pouching Machines, <strong>KHS</strong> AG, Kriftel<br />
Tel: +49/61 92/4 91 – 123<br />
E-mail: thomas.matheyka@khs.com<br />
OOF. PRECISE. FLEXIBLE. FUTURE PROOF. PRECISE. FLEXIBLE. FUT
“Globalization is entering<br />
a new phase”<br />
The Migros founder, Gottlieb Duttweiler, shaped Swiss economic<br />
history with a genius for business, tenacious fighting, bold ideas,<br />
and a strong sense of social responsibility. This description is<br />
taken from the GDI website (Gottlieb Duttweiler Institute, Switzerland).<br />
Gottlieb Duttweiler established this independent research<br />
institute in 1962 at the age of 74. To this very day, the institute’s<br />
remit includes monitoring of developments in global markets<br />
and registering of trends and counter-trends that are relevant<br />
for the economy and society. As set out by Gottlieb Duttweiler,<br />
and in keeping with the guiding principle of “Focus on<br />
people, not capital”, the Gottlieb Duttweiler Institute is today<br />
regarded as one of the leading European think tanks for economy<br />
and society. Reason enough for <strong>KHS</strong> journal to ask CEO Dr.<br />
David Bosshart which factors will decisively shape the global economic<br />
and social development in the future.<br />
<strong>KHS</strong> JOURNAL: The Gottlieb Duttweiler Institute is a global<br />
household name and has a reputation for identifying developments<br />
at an early stage. In its Agenda 20<strong>08</strong>, GDI states that<br />
“Globalization is entering a new phase”. Which new phase will<br />
this be?<br />
DR. DAVID BOSSHART: We are seeing a drastic increase in the number<br />
of issues that are relevant for companies. Let’s look at the<br />
financial markets, for example. Over recent years, we have seen<br />
a great many innovations, and private equity has become increasingly<br />
important. The banks have taken a leading position in the<br />
economy, while the influence of politics has been declining.<br />
This led to a growing gulf between the economy and politics.<br />
Recreating a balance in this area is a demanding task. In addi-<br />
Interview with Dr. David Bosshart,<br />
CEO of Gottlieb Duttweiler Institute, Switzerland<br />
tion, through today’s wealth of information sharing options we<br />
have reached an unprecedented level of communication. Take<br />
India, for example: Within the last few years, 350 million people,<br />
who previously had never even seen a conventional landline<br />
telephone, obtained cell phones and access to the Internet. On<br />
the one hand, this is progress, of course, but on the other hand,<br />
this progress has dynamic effects that are increasingly difficult<br />
to predict. After all, more information and more communication<br />
invariably also always means more potential for conflict. All in<br />
all, for me the new phase of globalization looks positive from an<br />
economic perspective, because globally, wealth is increasing,<br />
but on the other hand the political controllability is decreasing,<br />
and risks for companies in relation to production and the financial<br />
markets are increasingly difficult to narrow down.<br />
° What exactly does this situation mean for small, medium,<br />
and large companies?<br />
* The question of the right company size and the envisaged distribution<br />
area is becoming increasingly important in the future.<br />
This means that even for large companies it may not necessarily<br />
be beneficial to aim for global player status. Manageability,<br />
controllability, and risk reduction will become increasingly important,<br />
and it may well be advantageous to concentrate on markets<br />
offering high planning reliability.<br />
° What criteria should companies use as the basis for selecting<br />
suitable markets?<br />
* In the past, many companies felt they had to have a global<br />
presence, not least for prestige reasons. In reality, a rush towards
global presence is often not necessarily beneficial. Companies<br />
should examine the countries in which they are or want to be<br />
active from a long-term perspective. For the envisaged markets,<br />
the focus should not just be on current growth potential. Instead,<br />
companies should closely examine all stability indicators, including<br />
the prevailing value systems.<br />
° In this context, do you expect competition between the world<br />
markets to increase further in future?<br />
* Competition is definitely increasing. However, the real conflicts<br />
will take place in the area of supply. In my view, it is clear<br />
that, if we don’t get to grips with agriculture and energy at a<br />
global level, it will be impossible to sort out industrial issues. In<br />
theory, we can live without cars, but not without food and water.<br />
With increasing world population, these issues will become increasingly<br />
pressing. “From the region for the region” could be a guiding<br />
principle, which the food retail sector is already beginning<br />
to pick up, particularly in the developed countries. In addition,<br />
we need products that take proper account of environmental<br />
aspects, such as CO 2 emissions.<br />
° This sounds like a redefinition of values.<br />
* Exactly. In the future, competition will increasingly concentrate<br />
on a competition of values. Consumers will ask which products<br />
offer which values. In the developed countries, this has already<br />
started to happen. The Swiss Coop retail chain is a good example.<br />
Consumers for whom price is the key value will chose “entry-level<br />
products” labeled with a blue dot, which, although produced according<br />
to government regulations, do not incorporate values such as<br />
dialog+opinion °<br />
Dr. David Bosshart is CEO of the Gottlieb Duttweiler Institute in Rüschlikon,<br />
Zurich. The independent institute for economic and social studies is engaged in<br />
worldwide research activities. Speakers and guests who have shaped the GDI<br />
over the years include famous figures such as Ludwig Erhard, Friedrich Dürrenmatt,<br />
Václav Havel, Albert Alessi, Daniel Bernard, and many more. Dr. Bosshart<br />
has been CEO of the GDI since 1999. His work focuses on the future of consumption<br />
and social change, management and culture, globalization and political philosophy.<br />
He has written numerous international publications and is a multilingual<br />
expert and sought-after keynote speaker in Europe, U.S.A., and Asia.<br />
“organic” or “produced locally”, etc. Consumers seeking additional<br />
values can choose more expensive products with different labels.<br />
° You mentioned the risk of future food and energy shortages.<br />
This would mean rising prices. Doesn’t this mean that we will<br />
reach a point when the price will once again become the<br />
decisive value for consumers?<br />
* This is indeed the case in developing countries, where the<br />
focus is on meeting basic needs. In the developed countries, on<br />
the other hand, the basic needs are covered, and health is becoming<br />
one of the key values for which consumers are willing to pay<br />
more. Let’s take a brief look into the past: About 100 years ago,<br />
50% of income was still being spent on food in developed countries.<br />
Today this figure has fallen to 9% in Switzerland. Consequently,<br />
the last few generations have experienced an almost continuous<br />
reduction in food prices. This trend cannot and will not<br />
continue.<br />
° Does this mean that companies from the beverage and food<br />
sectors would be well advised to continue moving towards<br />
health and to focus marketing campaigns more on product<br />
quality?<br />
* Of course. More and more consumers are seeking quality and<br />
values associated with quality such as transparency, decency, and<br />
confidence. They want to know where their food, drinks, and<br />
other consumer goods come from, what they contain and under<br />
what conditions they were produced. In the new phase of globalization,<br />
consumers, the retail industry, and production companies<br />
will be called to account even more strongly than in the past.<br />
18*19
In this context, another key factor incidentally is the increasing<br />
responsibility of companies and the retail industry in terms of<br />
quality assurance at several levels. We need excellent product<br />
quality, service quality and innovation quality – in other words,<br />
we need quality as a whole. We need to look at the entire life<br />
cycle of each product, starting from design right up to disposal.<br />
° Which role do packaging and design play in this holistic scenario?<br />
* Packaging and design are key aspects. It goes without saying<br />
that the aesthetics of products and their attractive appearance<br />
also represent values, although this doesn’t mean that packaging<br />
has to be elaborate. The key is to omit anything that is superfluous,<br />
especially those things that don’t serve to highlight product<br />
quality from a consumer standpoint. The question is: How can I<br />
combine abstention and hedonism in a pleasurable way?<br />
° For many companies, ensuring quality at several levels is only<br />
possible if suppliers provide top quality. Is cooperation with<br />
suppliers therefore likely to become an even more important<br />
factor than it is already?<br />
* Absolutely. Cooperation with suppliers who have the same<br />
mindset is vital. Long-term cooperation on a firm basis results<br />
in win-win-win situations. Vertical cooperation will therefore<br />
undoubtedly become increasingly in future.<br />
° How important will creativity and innovational spirit be for<br />
business success in future?<br />
* Creativity and innovational spirit are decisive factors, particularly<br />
in Europe. Asian countries such as China have traditionally<br />
focused on cheaper production and copying. I consider America<br />
as particularly strong in marketing and in the field of hightech.<br />
It is difficult to predict how the picture will change in the<br />
“The small are the most resilient, vital, and in a true<br />
democracy, the strongest.”<br />
long term, although it is clear that we will see more and more<br />
interlacement. For example, acquisitions in the field of participation<br />
financing are likely to provide access to European creativity<br />
and European know-how. In this context, the recent takeover<br />
of the British carmaker Jaguar by the Indian car manufacturers<br />
Tata Motors had an almost symbolic character, because it could<br />
be regarded as a process of “reverse colonialization”.<br />
° “Focus on people, not capital” is a guiding principle of the<br />
Gottlieb Duttweiler Institute. Will this guiding principle<br />
become more significant in a new phase of globalization?<br />
* The focus will no doubt increasingly shift to social responsibility<br />
as a value that reaches into all activities of a company. A<br />
company generating a large proportion of its added value in a<br />
defined home market, reinvesting there, and ensuring sustainable<br />
job creation will place even greater importance on this than<br />
in the past.<br />
° How will the relationship between employees and companies<br />
change?<br />
* Employees will increasingly seek good employers offering<br />
maximum advancement. The times when job hopping every<br />
two years was fashionable are over. Employees who can identify<br />
with the corporate culture and see scope for advancement<br />
will stay.<br />
° How would you envisage a corporate culture that attracts<br />
good people?<br />
* I feel we need a variety of different corporate cultures. Employees<br />
will choose the corporate cultures that suit them, because in<br />
the future good people will tend to choose their employer rather<br />
than the other way round. All corporate cultures should give<br />
employees a high degree of responsibility. Each individual should
make a significant contribution to the company’s success, and<br />
each individual employee can expect something in return.<br />
° What exactly do you mean by “something in return”<br />
* I’m particularly referring to respect, integration in a positive<br />
corporate atmosphere that is characterized by mutual trust, and<br />
performance-related pay. Additional benefits such as company<br />
cars, daycare centers, etc. will automatically be part of a functioning<br />
corporate culture.<br />
° The role of women in the world of employment is being discussed<br />
worldwide. How will this role change?<br />
* We are seeing this change already today: In countries where<br />
women don’t play a significant role in the economy, growth is<br />
automatically inhibited. It is quite easy to prove that women are<br />
generally better able to cope with complex tasks than men. We<br />
therefore need teams comprised of both men and women, particularly<br />
for complex projects. In my view, the role of women in<br />
the world of work will continue to gain in significance, both in<br />
developed as well as in developing countries.<br />
° Currently, we are still distinguishing between developed markets<br />
and markets in development. Is it possible to predict<br />
when market development will have converged?<br />
* In my view, the main aspect in a global scenario is peace.<br />
Progress is only possible if peace prevails. Progress should be<br />
steady, and never too fast. If the gap is too wide, the middle class<br />
will not be strong enough. A stable middle class is imperative<br />
for orderly growth, because middle class essentially means hope<br />
for a better life for the family. If the middle class dies off, hope<br />
also dies off. It is difficult to provide a general answer to the<br />
question of the time period for the convergence between developed<br />
and developing countries. Nevertheless, I think that, based<br />
dialog+opinion ° Interview with Dr. David Bosshart<br />
on an optimistic forecast, China as the largest Asian country may<br />
have reached the economic level of the United States by 2<strong>02</strong>0,<br />
although in this scenario certain questions will no doubt gain in<br />
significance, such as: Will China be affected by overaging? Will<br />
there be enough healthy people in gainful employment in 2<strong>02</strong>0?<br />
These aspects indicate the importance of investment in health<br />
and education in developing countries.<br />
° What is your view on a convergence of lifestyle habits in Europe?<br />
* Basically, I would like to state that it is good to have an economically<br />
strong Europe, although a cultural Europe must always<br />
be considered in addition to an economic Europe. One can’t<br />
exist without the other. In terms of cultural development, there<br />
are tremendous differences within Europe, which can’t simply be<br />
swept away over a few decades of prosperity. I see Europe as an<br />
experiment, and I have no doubt that genuine growing together<br />
will take longer than another generation. Incidentally, the process<br />
of growing together of European countries is very different from<br />
the situation in the United States, where the focus is on the “American<br />
way of life”, i.e. independent, success-oriented individualism.<br />
The key question long-established citizens and migrants<br />
alike are asking themselves is how they can implement the “American<br />
way of life”, and this is a strong integrating factor.<br />
° Can we conclude from your example that the history deserves<br />
close examination when companies enter new markets?<br />
* Of course. Both the political history and the culture are key<br />
criteria. I can’t stress this often enough: Companies who only<br />
take a cursory look at economic aspects when they enter new markets<br />
are taking a big risk. What counts is a holistic view of a<br />
market based on a carefully planned market entry strategy.<br />
° Dr. Bosshart, many thanks for this interview.<br />
20*21
BEER<br />
The Asahi Group now operating<br />
27 filling systems from <strong>KHS</strong><br />
FOR THE WORLD<br />
The Japanese Asahi Group has ambitious aims: The company intends to<br />
become one of Asia’s leading suppliers to the beverage, food, and<br />
health sectors, and is well on its way to achieving this goal.<br />
Outstanding product quality and <strong>KHS</strong> technology play a significant role.<br />
The Japanese love their traditional cuisine. An extensive<br />
choice of beverages complements the wide range<br />
of local rice and fish dishes. One of the big players<br />
in the Japanese beverage market is the Asahi Group,<br />
which started off as a brewery. It is the undisputed<br />
market leader in the beer sector. Based on this success,<br />
Asahi is well on its way to becoming an established<br />
force in the Japanese food and health industry.<br />
The Group has a long-term growth strategy for<br />
these areas. Hitoshi Ogita, President and COO of Asahi<br />
Breweries, Ltd., has a clear concept: “We intend to<br />
make the Asahi Group the market leader in the bev-<br />
erage, food, and health sectors in Asia.” In the past,<br />
the focus has been on alcoholic drinks, as evidenced<br />
by sales figures. 2007: 69.1%, while non-alcoholic<br />
beverages had a share of 20.5%. The strongly growing<br />
food and health sector made a 4.6% contribution<br />
to Group sales. Around 6% of sales originated from<br />
areas such as logistics and restaurant management.<br />
An important aspect for the success of the company<br />
is its wide range of products. Asahi offers something<br />
for every taste. Take beer, for example, where<br />
Asahi has its roots: Established in 1889, the Osaka<br />
Beer Brewing Company received its first Grand Prix
Left Very popular in Japan: guided tours of Asahi breweries.<br />
Right <strong>KHS</strong> PU control: a key quality factor for the modular Innopas C pasteurizer solution.<br />
award for Asahi beer as early as 1893 at the World<br />
Fair in Chicago and again a few years later.<br />
During its long history, Asahi has repeatedly set<br />
new trends. For example in 1900, when the company<br />
presented Japan’s first bottled draft beer. Or in 1958,<br />
the year when Asahi was the first Japanese brewery to<br />
start filling beer in cans. In 1987, the company revolutionized<br />
the Japanese beer industry with the introduction<br />
of Asahi Super Dry, the first Japanese dry beer.<br />
TOP SUCCESS WITH TOP BRANDS<br />
Twenty years later, Asahi Super Dry still has an impressive<br />
70% share of Asahi Breweries’ beer, Happoshu and<br />
New Genre sales. But the company never relied only<br />
a single brand: In addition to Asahi Super Dry the product<br />
range includes Jukusen, Asahi Stout, Asahi Black,<br />
Kohaku no Toki keg beer and Kita no Shokunin, while<br />
Asahi also fills Miller Special and Löwenbräu under<br />
license and sells imported Bass Pale Ale, Tsingtao Beer,<br />
and Bellevue Kriek.<br />
Happoshu and New Genre beverages are specialties<br />
in the Japanese beverage market. Happoshu<br />
is a beer-like beverage produced with very low malt<br />
content, while no malt at all is used for New Genre.<br />
The Japanese love these new varieties. One reason for<br />
their huge success is the fact that in Japan beer tax<br />
is based on the malt content, among other parameters,<br />
so that the new beverage types are cheaper than<br />
conventional beer. Happoshu has a 12.3% share and<br />
New Genre a 6.1% share of total Asahi sales, with<br />
further strong growth expected. Asahi’s total sales<br />
figure for 2007 was nearly 24 million hectoliters, equiv-<br />
alent to a market share of 49.4%. In Japan, the Group<br />
has been the market leader since 2001.<br />
Asahi not only has ambitious aims for the<br />
domestic market, it also has a strong presence abroad.<br />
Asahi Super Dry is now regarded as one of the ten<br />
main beer brands worldwide. Internationally the company<br />
relies on a license production strategy, which<br />
offers advantages in terms of short routes, reliable<br />
partners, and local production. According to Noriyuk<br />
Karasawa, Director and Executive Officer, Senior General<br />
Manager Production Headquarters Asahi Breweries,<br />
Ltd., outside Japan Asahi will focus predominately<br />
on the growing markets in China and South-<br />
East Asia in future: “In China we expect significant<br />
growth, not least against the background of the 20<strong>08</strong><br />
Olympics.” Asahi has already been active in China<br />
since 1994 with four joint ventures, brewing Chinese<br />
brands as well as Asahi Super Dry. In 2006, the four<br />
partner companies produced around 6.37 million hectoliters<br />
of beer. Further important foreign markets<br />
are Thailand (licensee: Boon Rawd), the UK (Sheperd<br />
Neame), Czech Republic (Staropramen), and Canada<br />
(Molson Breweries).<br />
Asahi sells around 63% of its beer in cans with<br />
a wide range of sizes between 135 milliliters and 1,000<br />
milliliters. Glass bottles in sizes between 334 and<br />
1,957 milliliters have a market share of 20%. A special<br />
highlight is that Asahi is one of the few breweries<br />
offering beer in aluminum bottles, which enabled<br />
the Group to attract a fine circle of connoisseurs.<br />
Around 17% of total sales are filled in kegs (5 to 30<br />
liters) for the catering trade.<br />
task+solution °<br />
22*23
2<br />
THUMBNAIL PORTRAIT: ASAHI<br />
* Nine production facilities in Japan<br />
* Market leadership with a 49.4% share of the market<br />
* History<br />
1889 Osaka Beer Brewing Company is founded<br />
1893 First award for Asahi beer the World Fair in<br />
Chicago<br />
1900 Market introduction of draft beer in Japan<br />
1958 Market introduction of canned beer in Japan<br />
1987 Asahi presents the first dry beer in Japan.<br />
* Strong brands Asahi Super Dry (68% share of turnover),<br />
Jukusen, Asahi Stout, Asahi Black, Kohaku<br />
no Toki keg beer, Kita no Shokunin<br />
PROVEN TECHNOLOGY PARTNERSHIP<br />
Asahi and <strong>KHS</strong> have been brewing technology partners<br />
for decades. The partnership began in the early<br />
1960s. At the time, the company invested in mechanically<br />
controlled filling systems: “We were and continue<br />
to be very satisfied with these systems, although<br />
as a modern and innovative brewery new investments<br />
naturally focus on state-of-the-art equipment,” says<br />
Karasawa. Take electronically controlled filling systems,<br />
for example. This was relevant when investment<br />
in new technology was recently required at two locations:<br />
At the Fukushima brewery Asahi required new,<br />
gentle filler-rinser equipment, while at the Ibaraki<br />
brewery both an efficient filler solution and pasteurizer<br />
equipment with optimum hygienic performance<br />
were required.<br />
Left Noriyuki Karasawa, Director and Executive Officer, Senior<br />
General Manager Production Headquarters Asahi Breweries,<br />
Ltd.: “Besides the high quality of the technical solutions<br />
offered by <strong>KHS</strong>, we value the company’s know-how as a global<br />
player. Center Aluminum bottle. Right canned beer: The big<br />
seller for Asahi.<br />
Today a total of 27 <strong>KHS</strong> filling systems are in operation<br />
at Asahi breweries in Japan, 14 of which are used<br />
for cans, 8 for glass bottles, 4 for kegs, and 1 for aluminum<br />
bottles. Karasawa emphasizes, “In addition to<br />
the high quality of the technical solutions offered by<br />
<strong>KHS</strong>, we value their know-how relating to different<br />
markets as a global player for filling and packaging<br />
technology.”<br />
RINSER-FILLER AT FUK<strong>US</strong>HIMA:<br />
GENTLE AND FLEXIBLE<br />
The rinser-filler monoblock at Fukushima operates with<br />
a mechanically controlled Innoclean FR-EM singlechannel<br />
rinser and the computer-controlled volumetric<br />
Innofill DVF pressure filling system. The bottomup<br />
filling method with long filling tubes is particularly<br />
gentle and reduces oxygen pickup to a minimum.<br />
The flexible and future oriented solution system is<br />
already prepared for processing PET bottles in future.<br />
The only retrofit that would be required is a neck<br />
handling system for conveying the PET bottles.<br />
FILLING SYSTEM AT IBARAKI:<br />
EXACT AND EFFICIENT<br />
The new Innofill DVD can filling system installed at<br />
the Ibaraki brewery offers an optimum solution with<br />
regard to filling accuracy. The electromagnetic induction<br />
flowmetering system integrated in the computercontrolled<br />
volumetric filler ensures maximum filling<br />
accuracy. With conventional filling level systems, fill<br />
level variations were experienced in some cases when<br />
cans from different manufacturers were used. Karasawa<br />
is impressed by the new filling system: “The<br />
system offers high line efficiency, a factor that is very<br />
important for us. And in addition, this filling system
also offers scope for new can developments within the<br />
brewery group, which means we are already equipped<br />
for the future today.”<br />
PASTEURIZER AT IBARAKI: MODULAR AND<br />
PRECISE<br />
Ibaraki also invested in <strong>KHS</strong> pasteurizer technology<br />
and installed an Innopas C double-deck pasteurizer.<br />
Thanks to its modular design, the pasteurizer is able<br />
to meet all customer requirements down to the last<br />
detail. The system calculates the dynamic temperature<br />
profile for all products to be pasteurized and the<br />
respective packaging. This ensures the correct temperature<br />
and PU values and the associated heat consumption<br />
levels. Director and Executive Officer Noriyuki<br />
Karasawa sums it up, “With <strong>KHS</strong> pasteurizing equipment<br />
we are once again on the safe side when it comes<br />
to quality.”<br />
The highlight of the system is the <strong>KHS</strong> PU<br />
control with automatic program changeover integrated<br />
in the Innopas C. If there is a product or can<br />
changeover, the pasteurizer automatically detects the<br />
last container from the old batch and the first container<br />
from the new batch. It then creates a gap<br />
between the old batch and the new batch and adapts<br />
the process as required without interrupting the pasteurization.<br />
Mechanical pushovers at the pasteurizer<br />
infeed and outfeed regulate the necessary separation<br />
of products. “It leaves nothing to be desired,<br />
especially since, as usual, <strong>KHS</strong> integrated Japanese<br />
control technology into the overall package as<br />
requested,” says Karasawa.<br />
State-of-the-art <strong>KHS</strong> technology was recently<br />
also installed and commissioned at the Asahi plant in<br />
Suita (Osaka), including a combined unit for pre-wash-<br />
task+solution ° Asahi Group with 27 filling systems from <strong>KHS</strong><br />
ing and main washing, an Innokeg Till CONTIKEG CKHR<br />
32/32 and an Innokeg Till CONTIKEG CFK 20/20 filler<br />
with a capacity of 1,100 kegs per hour, based on 19liter<br />
kegs. Key criteria for Asahi Brewery’s decision<br />
to use advanced <strong>KHS</strong> technology were the DCF system<br />
for optimizing the filling volume and the field satellite<br />
technology with minimum cabling effort and faster<br />
availability for production due to minimum installation<br />
and commissioning times.<br />
Oliver Schneider, Sales Manager, Business Area<br />
Far East/Australia, <strong>KHS</strong> AG<br />
Hideo Suzuki, President, <strong>KHS</strong> Japan Corporation<br />
fi<br />
INFOBOX<br />
• WEBSITE www.asahibeer.co.jp<br />
• CONTACT<br />
Oliver Schneider, Sales Manager, Business Area<br />
Far East/Australia, <strong>KHS</strong> AG, Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 26 23<br />
E-mail: Oliver.Schneider@khs.com<br />
Hideo Suzuki, President, <strong>KHS</strong> Japan<br />
Corporation, Osaka<br />
Tel: +81/6/49 60/47 11<br />
E-mail: hideo.suzuki@khs.com<br />
24*25
Coca-Cola Içecek relies on new technology<br />
Dry ACF for Coca-Cola<br />
Coca-Cola Içecek (CCI) is number ten among the Coca-Cola bottlers worldwide. The Turkish company<br />
is the first Coca-Cola bottler to receive an ACF line with dry sterilization from <strong>KHS</strong> as non-carbonated<br />
beverages play a major role in the company plans. CCI has also ordered a PET line for carbonated<br />
drinks. A company that continues to grow.<br />
With six production locations, Coca-Cola Içecek<br />
in Turkey is the undisputed market leader<br />
for both carbonated soft drinks and noncarbonated,<br />
alcohol-free beverages. And<br />
the company is looking for new challenges<br />
in Eurasia and the Middle East. The idea is<br />
to further expand the Turkish market and at<br />
the same time to focus on interesting countries<br />
such as Kazakhstan, Azerbaijan, Kyrgyzstan,<br />
Turkmenistan, Tajikistan, Jordan,<br />
Syria, and Iraq. After all, CCI is today already<br />
one of the ten Coca-Cola bottlers with the<br />
highest sales worldwide.<br />
The Corlu plant, located on the outskirts<br />
of the mega-metropolis Istanbul with<br />
around 20 million inhabitants, is the company’s<br />
most important site. Here, CCI bottles<br />
Coca-Cola brand products and produces<br />
PET preforms and PET bottles. As a producer<br />
of PET preforms, Corlu ranks as one<br />
of the largest plants in Europe and supplies<br />
the other CCI plants with a wide variety<br />
of packaging types ranging from the<br />
0.33-liter to the 2.5-liter family-size bottle,<br />
which is extremely popular on the Turkish<br />
market.<br />
Coca-Cola is clearly the leading product followed<br />
in second place by Fanta. Other carbonated<br />
brands in the range include Sprite,<br />
Schweppes, and Sen-Sun. But CCI is also<br />
strong when it comes to non-carbonated<br />
beverages. Fruit beverages such as Cappy,<br />
tea drinks such as Nestea, sports drinks such<br />
as Powerade, spring water such as Damla –<br />
all are included in the wide range of products.<br />
CCI boasted 2-digit overall growth<br />
rates the previous year and the upturn is<br />
expected to continue due to the rapid<br />
increase in buying power in the Turkish mar-
2<br />
THUMBNAIL PORTRAIT: COCA-COLA IÇECEK<br />
* Market leader in Turkey for carbonated and non-carbonated alcohol-free beverages<br />
* One of the top ten Coca-Cola bottlers worldwide<br />
* Six locations: Ankara, Bursa, Corlu, Izmir, Mersin and Mahmudiye<br />
* Wide range of varieties and containers<br />
* Two-digit international growth rates<br />
ket. High-priced non-carbonated beverages<br />
in particular have a great future.<br />
COMPELLING ACF TECHNOLOGY FROM <strong>KHS</strong><br />
With an innovative technical solution, CCI<br />
is now well prepared to cope with the boom<br />
in non-carbonated beverages: the first ACF<br />
(Aseptic Cold Filling) line in the Coca-Cola<br />
Group worldwide working with dry sterilization<br />
has been put into operation at the<br />
Corlu site. Praise from Ahmet Nuri Yilmaz,<br />
Operations Manager at the CCI plant in Corlu:<br />
“For us, all aspects of the process are impressive.<br />
And we have assured ourselves of the<br />
highest quality with the latest ACF equipment<br />
from <strong>KHS</strong>.” According to Yilmaz, the<br />
decisive factor was initially the basic advantages<br />
of the ACF process:<br />
* It is suitable for the most sensitive beverages<br />
* It provides outstanding microbiological<br />
safety<br />
* It retains the natural taste, flavor, and<br />
color of the beverage<br />
* We can safely do without preservatives<br />
In addition, dry sterilization scores further<br />
plus points versus the conventional but<br />
likewise completely microbiologically safe<br />
wet ACF process:<br />
* It saves rinsing water for bottles and<br />
caps and therefore cuts costs<br />
* It takes up considerably less space (15<br />
instead of 65 cubic meters of clean room<br />
volume)<br />
Selim Mizrahi, CCI Engineering Service Manager,<br />
sums it up, “<strong>KHS</strong> was attractive as<br />
the first supplier of this technical solution<br />
to the Coca-Cola organization worldwide,<br />
because we think <strong>KHS</strong> probably has the most<br />
comprehensive experience in the industry<br />
when it comes to the ACF dry sterilization<br />
process.”<br />
task+solution ° 26*27<br />
Left Turkey: Still CCI Group’s strongest market. Largest of six<br />
production facilities is Corlu.<br />
Center Mini-isolator technology: Keeps the clean room volume<br />
within the ACF monoblock as small as possible.<br />
Right Rinser-filler-capper monoblock of the “classical line”: The<br />
rinser cleans bottles with ionized air.<br />
As a brand name producer, Coca-Cola not only<br />
relies on a wide variety of products and different<br />
bottle sizes, but also on differently<br />
shaped PET bottle styles. The dry sterilization<br />
process is particularly suitable for this<br />
purpose. The sterilization medium for bottles<br />
and caps is hydrogen peroxide (H 2O 2).<br />
Bottle surfaces and caps treated with this<br />
medium are always completely wetted. The<br />
process even reaches any undercuts, edges,<br />
and angles, such as those found on ribbed<br />
bottles, and even sports caps. The stations<br />
of the line are described briefly below.<br />
Sterilization. The non-refillable<br />
PET bottles are conveyed by air conveyors<br />
to the ACF monoblock and then over an<br />
infeed plate that requires no format parts,<br />
to the sterilizer / activator area for internal<br />
and external sterilization with H 2O 2.<br />
Vaporized H 2O 2 is distributed evenly on the<br />
bottle surfaces by condensation. The<br />
appearance of condensation on all the inter-
Ahmet Nuri Yilmaz, Operations Manager of the production facility in Corlu (left), and Selim Mizrahi, CCI<br />
Engineering Services Manager, agree: “With <strong>KHS</strong> technology, we believe we’re playing it on the safe side.<br />
In <strong>KHS</strong>, we are dealing with a trusted partner.”<br />
nal and external surfaces of the bottle means<br />
that the condensation process is also very<br />
easy to check visually. The actual sterilization<br />
process starts as soon as warm air flows<br />
into the plastic bottle in an activator area<br />
connected to the sterilizer. The H 2O 2 displaced<br />
by warm air generates free radicals,<br />
which immediately attack the cells of<br />
microorganisms. At the same time, the H 2O 2<br />
dries without leaving any residue. Two activators<br />
are used at CCI Corlu to ensure that<br />
this is absolutely the case for all conceivable<br />
filling situations.<br />
Filler. After sterilization, the PET<br />
bottles pass directly to the pressureless freeflow<br />
filler. Depending on the product, the<br />
line fills volumetrically in one or two steps<br />
by means of electromagnetic inductive<br />
flowmetering for exact fill volumes. Other<br />
benefits: no time is lost for changeover when<br />
changing bottles types (data are stored electronically)<br />
and the central filler control is<br />
fully automatic. The result is process reliability<br />
at the press of a button – with the<br />
AIS plant information system.<br />
Capper. Both classical plastic<br />
screw caps and sports caps are used. The<br />
caps are sterilized in separate units. Special<br />
features include separating the capping<br />
motion into the rotary movement of<br />
the cap and the vertical movement of the<br />
bottle. Each capping spindle is equipped<br />
with its own servo drive. The stations operate<br />
entirely without lubricants for maximum<br />
microbiological safety.<br />
Mini-isolator. To keep the clean<br />
room volume within the ACF block as small<br />
as possible, <strong>KHS</strong> uses so-called mini-isolator<br />
technology. The basic principle of the<br />
compact isolator technology involves containing<br />
only the PET bottle guide elements<br />
in the sterilizer and activator as well as<br />
the filling valve bells in the filler carousel<br />
and the capping heads in the capper. All<br />
moving parts are kept outside the sterile<br />
clean room. The system operates under<br />
clean room class 100 conditions only in<br />
the mini-isolator zone. HEPA (high efficiency<br />
particulate air) filters provide a constant<br />
supply of sterile air. An important<br />
aspect is that during antiseptic operation,<br />
the system measures and stores all actual<br />
process values, which can be called up as<br />
required at all times. A code on every PET<br />
bottle provides information relating to the<br />
rinsing, filling, and capping process as well<br />
as the inspection results should there be<br />
any queries from the consumer.<br />
Check. Fill levels and caps are<br />
checked outside the ACF block using<br />
advanced camera technology. Squeezers<br />
are used to check for leaks.<br />
Labeler. Two labeling machines<br />
feed the PET bottles alternatively with rollfed<br />
or shrink-sleeve labels.<br />
Packer / Palletizer. The bottles<br />
then pass to the Innopack Kisters SP shrink<br />
packer. The six-axis Innopal RK 6 articulated<br />
robot palletizes the packs (a roller carpet<br />
head handles the shrink packs with care).<br />
As this is the first ACF line with dry<br />
sterilization within the worldwide Coca-Cola<br />
Group, Ahmet Nuri Yilmaz expects many visitors<br />
in the near future. CCI Corlu could<br />
almost set a good example and serve as ACF<br />
training center. “Because,” says Selim<br />
Mizrahi, “we assume that there will be further<br />
investment in this new technology over<br />
the next few years – both in Turkey and<br />
worldwide.”
CLASSICAL PET LINE<br />
While the ACF line was being commissioned,<br />
CCI ordered yet another classical PET line<br />
from <strong>KHS</strong> to bottle carbonated soft drinks.<br />
Yilmaz says, “<strong>KHS</strong> has been our trusted partner<br />
since the production facility was set up<br />
in 1997. We are so satisfied that CCI Corlu<br />
has literally become a <strong>KHS</strong> stronghold.” And<br />
indeed, the Corlu plant is nearly exclusively<br />
equipped with <strong>KHS</strong> system technology – six<br />
lines in all are currently in operation. Mizrahi<br />
adds, “Although the ACF line is something<br />
special because of its novelty value, we are<br />
equally satisfied with our new soft drinks<br />
line, especially since it also offers many special<br />
features.”<br />
A very special rinsing system is used<br />
in the newly installed <strong>KHS</strong> line for carbonated<br />
soft drinks, for instance, which once<br />
again emphasizes the company’s high environmental<br />
friendliness. The computer-controlled<br />
Innoclean FR-ER single-channel rinser<br />
uses ionized air as the rinsing medium. The<br />
basic principle involves blowing out the bottles<br />
with ionized air to electrostatically discharge<br />
and clean them. Air serves as a carrier<br />
medium for ions that produce a con-<br />
task+solution ° Coca-Cola Içecek relies on dry ACF<br />
Left Labeling: a roll-fed labeling machine in the carbonated soft drinks line. Center Packing: shrink packs in both the ACF line<br />
as well as the “classical line”. Right Shrink tunnel: Temperatures are adapted to the film quality and pack size.<br />
trolled neutralization of the electrostatic<br />
charge in bottles. Once the electrostatic<br />
charge is neutralized, any particles clinging<br />
to bottle walls are removed. The main<br />
advantages of the system:<br />
* It saves precious water<br />
* It saves time<br />
* It can be implemented in rinsers that<br />
are half the size<br />
* It does not burden the product being<br />
bottled with remaining water<br />
* It ensures that the statically neutral bottles<br />
do not attract particles in the ambient<br />
air while being transferred to the<br />
filler<br />
The rinser is contained in a monoblock<br />
together with the computer-controlled<br />
Innofill DRV volumetric, pressure filling<br />
system that operates with exceptional precision<br />
without filling tubes using electromagnetic<br />
inductive flowmetering. Another<br />
highlight is the Innoket RF labeling<br />
machine. Each of the two labeling units<br />
is equipped with a double reel stand for<br />
fast reel changing to minimize machine<br />
downtime.<br />
The new <strong>KHS</strong> line for carbonated soft drinks<br />
is used primarily to fill the 2.5-liter PET family<br />
bottle. Yilmaz says, “To achieve the highest<br />
possible system efficiency, we pursue a<br />
strategy of switching bottle and product<br />
types as little as possible for all of our lines.”<br />
A strategy that pays off.<br />
Erhard Magin, Director Business Area Africa,<br />
Middle East and Southern Europe, <strong>KHS</strong> AG<br />
Hubert Schiffer, Sales Africa, Middle East and<br />
Southern Europe, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
28*29<br />
• WEBSITE www.cci.com.tr<br />
• CONTACT<br />
Erhard Magin, Director Business Area<br />
Africa, Middle East, and Southern Europe,<br />
<strong>KHS</strong> AG, Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 26 75<br />
E-mail: erhard.magin@khs.com<br />
Hubert Schiffer, Sales Africa, Middle East and<br />
Southern Europe, <strong>KHS</strong> AG Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 26 71<br />
E-mail: hubert.schiffer@khs.com
2<br />
Especially manufacturers of health products must be able to rely<br />
on perfect results in packaging. The technological keywords are<br />
flexible, gentle, durable, strong. That is why Anton Hübner<br />
relies on <strong>KHS</strong> labeling quality.<br />
Stick- iveness<br />
to-it-<br />
Anton Hübner, provider of innovative health products, applies labels perfectly<br />
Since time immemorial, human beings have relied on the power of<br />
herbs to fight disease. One of those people was the Black Forest<br />
priest Hurst, who in 1920 was looking for an effective way to fight<br />
respiratory disorders. At that time, manual workers suffered from<br />
these diseases, especially those in the domestic textile industry.<br />
Paging through a book of herbal remedies, Hurst stumbled across<br />
an herbal medication recipe written by his ecclesiastical counterpart<br />
Sebastian Kneipp.<br />
Hurst continued the development of that recipe, adding<br />
special Black Forest medicinal herbs. In the mid-1920s, Hurst joined<br />
forces with the pharmacist Eduard Hiepe to launch this natural cold<br />
remedy to market, under the name of “Tannenblut”. Its healing<br />
power was soon well-known, piquing the interest of businessman<br />
Anton Hübner, who purchased the license for Tannenblut in 1936<br />
and started industrial production of the medication. For about 25<br />
years, Tannenblut remained the only product of Anton Hübner <strong>GmbH</strong>.<br />
THUMBNAIL PORTRAIT: ANTON HÜBNER<br />
1920 Tannenblut cold remedy is developed<br />
1936 Anton Hübner acquires Tannenblut license<br />
1968 Operations taken over by Wilhelm Oberle and product line expanded<br />
1988 Acquired by Wella AG<br />
2000 Acquired by Nordzucker AG<br />
20<strong>08</strong> About 200 products, with a strong distribution channel through health<br />
food stores. Export to about 30 countries<br />
Eventful history …<br />
In 1968, the company gradually expanded its product line when<br />
Tannenblut was joined by new brands, such as Original silicea Balsam®<br />
and denk fit!. By the end of the 1990s, the company had<br />
changed hands several times, before Nordzucker AG took it over in<br />
2000.<br />
… with high-quality brands …<br />
Over the years, the silicea brand has become the company’s best<br />
selling product now representing about a third of Hübner’s total<br />
sales. The core of the brand is the Original silicea Balsam®.<br />
… with a unique silicic acid gel …<br />
One of the success factors of the silicea products is silicic acid gel<br />
that Hübner produces without preservatives using one of the world’s<br />
most unique sterile processes. The company utilizes the circumstance<br />
that the ingredient silicon turns into silicic acid gel when<br />
combined with water. Used externally, the gel helps to sooth sunburns,<br />
as well as minor skin injuries. But used internally, silicic<br />
acid reveals its beneficial effects, encouraging controlled nutrient<br />
transport to the skin cells, for instance.<br />
… with strong distribution channels through health food stores …<br />
Marketing silicic acid products is equally as unique as the company’s<br />
production process. Hübner sells its products in Germany primarily<br />
through health food stores with silicea as the single most-sold<br />
product in these stores. Sebastian Ott, Production and Engineering<br />
Manager at Anton Hübner <strong>GmbH</strong> & Co. KG, explains, “Hübner<br />
has grown up with health food stores as a distribution channel.<br />
In Germany, we’re sticking with that distribution route. Since there<br />
is no comparable health food store structure abroad, our sales activ-
Top Perfect labeling results: For Hübner, the main reason to decide<br />
on <strong>KHS</strong> labeling technology.<br />
Bottom Advantage of cam control: The lower chucks oscillate to<br />
ensure optimal brush-on label application.<br />
ities are oriented to each market entirely on a case-by-case basis.”<br />
Even today, Anton Hübner realizes nearly one third of its sales in<br />
more than 30 countries – and with an upward trend.<br />
… and a broad product range<br />
Today, Hübner offers an assortment of nearly 200 different products,<br />
ranging from nutritional supplements to cosmetics, and<br />
even numerous medications. All products must meet the same high<br />
quality requirements. That starts with the selection of high-quality<br />
raw materials, continues with gentle processing, and ends with<br />
perfect packaging quality.<br />
LABELING TECHNOLOGY FROM <strong>KHS</strong><br />
Keyword packaging: Hübner’s decision in favor of <strong>KHS</strong> labeling technology<br />
was not coincidental as Sebastian Ott explains, “The label<br />
is our first communication with the consumer at the point of sale.<br />
Exactness is our uppermost principle. With <strong>KHS</strong> technology, we’re<br />
staying on the safe side.” The labeling solution must meet the<br />
following requirements to satisfy these high expectations:<br />
* High performance<br />
task+solution °<br />
* Perfect results<br />
* Gentle package handling<br />
* Short product changeover<br />
A brief glance at the most important features of the Innoket ROLAND<br />
10 H labeler.<br />
HIGH PERFORMANCE: 9,000 BOTTLES PER HOUR<br />
The new labeler should also be prepared for future production expansion.<br />
The <strong>KHS</strong> Innoket ROLAND 10 H labeler fulfills that requirement<br />
perfectly. It is designed to label up to 9,000 bottles per hour.<br />
Today, Hübner labels about 13,000 bottles per day. That leaves<br />
plenty of room for growth. Ott says, “Growth, which would exhaust<br />
any conceivable labeling performance is absolutely possible here<br />
at Hübner in the medium term.” For more than 20 years, <strong>KHS</strong> and<br />
Hübner have been technology partners in the field of labeling. The<br />
old labeler was only retired because its performance could no longer<br />
keep up with the demand for increased performance.<br />
PERFECT RESULTS: NEARLY NO RANGE OF TOLERANCE<br />
Ott mentions another reason for the partnership: “<strong>KHS</strong> labeling<br />
technology offers us – and this point was decisive – the precision<br />
we need for applying each and every label.” The labeler is currently<br />
being used to apply adhesive pressure labels to 200- and 500-milliliter<br />
silicea plastic bottles. One labeling field is provided for<br />
each front and back label and virtually no range of tolerance to<br />
apply them. A slight bulge in the bottle surface designates the<br />
labeling fields. Ott says, “The label itself is designed so that on<br />
the left and right, and the top and bottom there is exactly two<br />
millimeters of clearance in the labeling field. Since we place primary<br />
emphasis on an attractive appearance, the range of tolerance<br />
is next to none.”<br />
30*31
Anton Hübner applies labels perfectly<br />
Sebastian Ott, Production and Engineering Manager (center) and Branislav Krznar, responsible machine technician<br />
(left) agree: “The kind of technical solution a growing company like Hübner needs.” Also pictured: Jan-Wilhelm<br />
Brückel, <strong>KHS</strong> AG, Hamburg.<br />
MAXIMUM FLEXIBILITY: VARIETY OF 54 DIFFERENT LABELS<br />
The adhesive pressure process offers quick changeover of dressing<br />
to ensure maximum flexibility. An especially important item for<br />
Hübner as the company uses a total of 54 different film label styles.<br />
With such a wide variety, the adhesive pressure process has genuine<br />
advantages over the wet glue process, since there is no need<br />
to change glue segments, label hoppers, and when changing over<br />
to another label style, all that is necessary is to change label<br />
reels.<br />
GENTLE HANDLING: NO ACCUMULATION PRESSURE<br />
In addition, the labeler must handle the plastic bottles particularly<br />
carefully. Which means, with as little accumulation pressure as possible.<br />
Two bottle flowgates prevent the build-up of accumulation<br />
pressure in the first place. The first bottle flowgate is directly<br />
upstream of the labeler while a second bottle flowgate is integrated<br />
into the feed screw.<br />
EXACT POSITIONING: LONGER FEED SCREW<br />
<strong>KHS</strong> has designed the feed screw so that it is ideally suitable for<br />
sensitive plastic bottles. Because it is longer than normal feed<br />
screws, it is able to space the containers particularly gently and<br />
distribute them perfectly. The centers of gravity of the bottles to<br />
be labeled vary depending on their composition. The position of<br />
the feed screw can be adjusted horizontally and vertically just as<br />
exactly.<br />
PERFECT LABELING: RECESSED LOWER CHUCK<br />
An infeed star feeds the bottles into the labeler carousel where<br />
lower chucks and centering bells hold the bottles and lock them<br />
in place. These chucks have recesses to ensure perfect, custom-<br />
fit labeling of square shaped plastic bottles. Of course, this system<br />
can be retrofitted later. Should Hübner decide to expand its<br />
variety of bottles in the future, <strong>KHS</strong> will provide appropriate bottle<br />
plates for the Innoket ROLAND 10 H.<br />
IDEAL BR<strong>US</strong>H-ON APPLICATION: CAM-CONTROLLED<br />
LOWER CHUCK<br />
In the labeler carousel, there are two adhesive label units for the<br />
front and back label. Cam control drives the lower chuck in the<br />
carousel, setting it into an oscillating movement after the labels<br />
are applied. This allows the labels to be optimally brushed on.<br />
After labeling, the bottles reach the outfeed star that can be equipped<br />
with an additional labeling assembly, opening up further label application<br />
options for Hübner such as lid or closure labels.<br />
SHORT CHANGEOVER: CLEARLY ARRANGED AND ACCESSIBLE<br />
The Innoket ROLAND 10 H reveals itself as being particularly efficient<br />
when it comes to changeover. When switching bottle types,<br />
format parts can be changed within a minimum amount of time and<br />
production can be quickly resumed. Sebastian Ott says, “Not only<br />
is the labeler compact, it also has a clearly arranged layout and is<br />
outstandingly accessible. For the limited amount of space we can<br />
provide for the labeling machine, that’s exactly the solution we<br />
need now and in the future.”<br />
Jan-Wilhelm Brückel, Marketing Manager, Labeling Machines, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.anton-huebner.de<br />
• CONTACT<br />
Frank Huckfeld, Product Support, Labeling Technology,<br />
<strong>KHS</strong> AG, Hamburg<br />
Tel: +49/63 70 33 71 17<br />
E-mail: frank.huckfeld@khs.com
Left Attractive labels: For perfect product presentation at the point of sale.<br />
Right Innofill UMG filling system: Extremely precise filling process.<br />
Kumbok-Ju relies on<br />
soju – and <strong>KHS</strong><br />
Tradition, so it is said, is not preserving the<br />
ashes but passing on the flame. This view<br />
of things is admirably confirmed by the<br />
South Korean beverage company Kumbok-<br />
Ju. For many decades, the company has<br />
specialized in the production of soju,<br />
Korea’s national drink. Soju – a light liquor<br />
distilled from the main ingredient rice in<br />
combination with wheat, barley, or sweet<br />
potatoes – has been enjoyed by the Koreans<br />
for several hundred years. Kumbok-Ju<br />
has succeeded in passing on the flame of<br />
this tradition – with new soju brands and<br />
a modern product appearance.<br />
Kumbok-Ju was founded in 1957 as<br />
Samsan Co. Ltd., and began by producing<br />
among other things brandy, gin, and wine.<br />
The soju production began a year after<br />
the company was established. In 1963<br />
came the hour of the soju brand Kumbok-<br />
Ju, and in 1975 the entire company was<br />
renamed after the successful drink. The<br />
main source of sales today is still soju, of<br />
which the company manufactures several<br />
styles under the Charm brand name with<br />
an alcohol content ranging from 19.7 to<br />
23 percent.<br />
There is also a lighter version: The Blue<br />
brand with only 17.9 percent alcohol.<br />
Younghue Shin, Vice President of the Kumbok-Ju<br />
group of companies: “We focus our<br />
two new soju developments particularly on<br />
the young generation and the female target<br />
group.”<br />
As the per capita consumption of<br />
soju in Korea is already very high, the overall<br />
market is not expected to grow at a<br />
significant rate. However, Kumbok-Ju is<br />
relying on an increasing market share of<br />
one percentage point per year.<br />
For all this, the quality of the products<br />
must always be right – an important<br />
guarantee for highest product quality is<br />
the right filling and packaging equipment.<br />
The management decided on innovative<br />
solutions from <strong>KHS</strong>. According to Shin,<br />
“<strong>KHS</strong> plant equipment gives us production<br />
and product reliability, and for the first<br />
task+solution °<br />
Tried-and-tested and high-tech do<br />
not have to be mutually exclusive.<br />
The South Korean soju manufacturer<br />
Kumbok-Ju combines both with<br />
the utmost success – and an<br />
exceptionally high-performance<br />
line from <strong>KHS</strong> also plays its part.<br />
Traditionally<br />
Progressive<br />
time makes future success possible in the<br />
form that we want.” The company has<br />
recently invested in a new <strong>KHS</strong> high-performance<br />
line with a capacity of 60,000<br />
360-milliliter glass bottles per hour.<br />
Installed upstream of the line are an<br />
Innopro COSMOS horizontal mesh filter<br />
and an Innopro ORION sheet filter.<br />
DEPALLETIZING STATION WITH<br />
INNOPAL PE AND DECRATING STATION<br />
WITH INNOPACK PPZ<br />
The crates are depalletized in the line by<br />
an Innopal PE. The machine lifts the entire<br />
stack of crates stacked in layers on the pallet<br />
to remove the empty pallet from the<br />
system. It then destacks the individual<br />
layers of crates from the bottom. The capacity<br />
of the depalletizer and the Innopack<br />
PPZ decrater is 100,000 bottles per hour<br />
each. This calculated overcapacity is nec-<br />
32*33
Bottom Innopal RS2 column-type robot:<br />
Stacks supplied crates in a crate magazine<br />
with 1,680-crate buffer capacity.<br />
Left Younghue Shin, Vice Presi-<br />
dent of the Kumbok-Ju<br />
company group: “We take our<br />
responsibility towards<br />
consumers very seriously.”<br />
essary, because the returned crates contain<br />
around 40 percent foreign and unusable<br />
bottles and bottles with screw caps.<br />
After sorting the bottles, the calculated<br />
60,000 bottles are left for further processing.<br />
Because of its high decrating capacity,<br />
a buffer table is incorporated immediately<br />
after the Innopack PPZ to ensure<br />
that the bottles are gently conveyed onward<br />
and to make optimum use of the available<br />
working area. When the bottles enter the<br />
buffer table, a patented chain guide separates<br />
the stream of containers into two<br />
sub-flows and feeds them past a stationary<br />
plow tip without contact. Multiple<br />
drives ensure an optimum scaling down of<br />
the conveying speed and a low-pressure<br />
transfer of the glass bottles onto the buffer<br />
system outfeed. Here, camera equipment<br />
is used to check the bottles themselves and<br />
2<br />
their discharge onto one of the three conveyor<br />
lanes in the system.<br />
The first conveyor line guides foreign<br />
bottles and flawed bottles directly out<br />
of the system. The second line conveys<br />
those bottles with screw caps to the decapper<br />
from where they are conveyed further<br />
to the bottle washing machine. Since it is<br />
important that there be no safety rings<br />
on the threads of the bottle, the system<br />
uses a camera monitoring system to check<br />
that there are none. Only flawless bottles<br />
pass directly to the Innoclean DM doubleend<br />
bottle washing machine over the third<br />
conveyor segment.<br />
BOTTLE WASHING STATION WITH<br />
INNOCLEAN DM<br />
Reasons for using this type of machine<br />
include optimum hygiene values achieved<br />
by keeping the dirty bottles consistently<br />
Right All from one source: Besides the filling and packaging<br />
equipment, <strong>KHS</strong> has also supplied the processing engineering<br />
equipment such as the Innopro COSMOS horizontal mesh<br />
filter… left … and the Innopro ORION sheet filter.<br />
THUMBNAIL PORTRAIT: KUMBOK-JU<br />
* Founded in 1957 as Samsan Co., Ltd.<br />
* 1958 Start of soju production<br />
* 1963 Introduction of the Kumbok-Ju soju brand<br />
* 1972 Founding of Kyong-Ju Beob Joo Co. who produces<br />
the rice wine of the same name<br />
* 1975 Samsan renamed Kumbok-Ju Co., Ltd.<br />
Soju<br />
* Company’s share of the market: around 10 percent<br />
* Main sales region: Gyeongsangbuk-do Province with<br />
90 percent market share; Export markets: Japan and<br />
China soon to be followed by the U.S.A. and Europe<br />
* Charm brand with an alcohol content ranging from<br />
19.7, 20, 21, and 23 percent<br />
* The Blue brand, 17.9-percent alcohol content<br />
* Andong premium brand<br />
Rice wine<br />
* Share of total sales: 15 percent<br />
* Kyong-Ju Beob Joo and Hwanrang brands<br />
separated from the clean bottles. Treatment<br />
times can be controlled individually<br />
by combining three in-line caustic baths.<br />
Heat insulation and heat recovery units<br />
also reduce energy and fresh water consumption.<br />
Environmentally friendly disposal<br />
of broken glass, labels, and waste is<br />
handled by special discharge systems.<br />
The Innoclean DM in operation at<br />
Kumbok-Ju is equipped with a special prewashing<br />
facility to ensure that even heavily<br />
contaminated and dirty bottles are perfectly<br />
cleaned. After draining any remaining<br />
liquids, two rotating tubes spray the<br />
bottles internally at high pressure enabling<br />
discharge of coarse impurities with outstanding<br />
efficiency. This in turn increases<br />
the service life of the caustic in the downstream<br />
caustic baths. In the caustic baths<br />
themselves, Kumbok-Ju relies on a combination<br />
of rotating and stationary sprays
to further increase the cleaning effect.<br />
Shin says, “<strong>KHS</strong> bottle washing equipment<br />
leaves nothing to be desired. We are more<br />
than pleased with the results.” An empty<br />
bottle inspection system checks the cleanliness<br />
of the bottles using triple side wall<br />
inspection, bottle base inspection, and bottle<br />
mouth inspection, and additionally<br />
inspects the threads and checks for residual<br />
liquids.<br />
FILLING STATION WITH INNOFILL UMG<br />
The 360-milliliter soju bottles and their<br />
narrow neck areas require a precision filling<br />
process, as even the smallest variations<br />
in height would give the impression of inaccurate<br />
filling at the point of sale and detract<br />
from the uniform presentation of the product.<br />
The mechanical Innofill UMG vacuum<br />
filling system ensures perfect filling results.<br />
The specified fill levels can be exactly determined<br />
by means of a return gas tube and<br />
a gas lock. The filling process ends as soon<br />
as the soju reaches the return gas tube.<br />
The drip-free filling process also prevents<br />
loss of product. The filling valve has only<br />
a few moving parts, which minimizes wear,<br />
reduces maintenance costs, and increases<br />
machine availability.<br />
A clamping star system at the filler<br />
outfeed feeds freshly filled and sealed bottles<br />
into the two-lane outfeed and to the<br />
task+solution ° Kumbok-Ju relies on soju – and <strong>KHS</strong><br />
automated full bottle inspection system.<br />
With this system, Kumbok-Ju has adopted<br />
a pioneering role in South Korea. In the<br />
past, only visual inspection was used in<br />
high-capacity bottling lines. Now automatic<br />
full bottle inspection systems are<br />
guaranteeing top quality standards for the<br />
first time.<br />
LABELING STATION WITH<br />
INNOKET KL 2<strong>08</strong>0<br />
Bottles that have passed this quality inspection<br />
now travel over a buffer table to the<br />
Innoket KL 2<strong>08</strong>0 labeling machine. Integrating<br />
buffer tables at key strategic points<br />
in the line ensures a disruption-free system<br />
flow. <strong>KHS</strong> has solved this problem at<br />
Kumbok-Ju in an extremely space-saving<br />
way.<br />
The labeling machine operates with<br />
two wet glue stations to apply shoulder and<br />
back labels. I. H. Kim, Engineering Manager<br />
of the Kumbok-Ju company group,<br />
says, “<strong>KHS</strong> has also provided top-level technology<br />
when it comes to labeling equipment.<br />
We are greatly impressed with the<br />
Innoket KL 2<strong>08</strong>0.” An Innocheck ETI inspection<br />
machine checks that the labels are<br />
perfectly seated and optimally applied.<br />
PACKING STATION WITH INNOPACK<br />
PPZ AND INNOPAL RS3 BGN<br />
COLUMN-TYPE ROBOT<br />
The crates washed by the <strong>KHS</strong> Innoclean<br />
KW crate washer and the bottles merge at<br />
the Innopack PPZ crater. An Innopal RS3<br />
BGN column-type robot palletizes the preformatted<br />
layer patterns using a clamping<br />
device. The three-axis robot works<br />
according to the SCARA principle, i.e. exclusively<br />
with horizontal and vertical movements.<br />
A special feature: As an alternative<br />
to packing the bottles in crates, the line<br />
can also be combined with a wrap-around<br />
packer. In this case, empty crates pass<br />
through the Innopack PPZ packer to the<br />
palletizer without processing. The robot<br />
is able to process the empty crates without<br />
difficulty with its two tables; one for<br />
palletizing empty crates and one for palletizing<br />
full crates or for palletizing wraparound<br />
packs. A truly integrated logistics<br />
solution, which allows parallel handling of<br />
full and empty crates as well as cartons.<br />
A further highlight is the integrated<br />
crate magazine with a maximum buffer<br />
capacity of 1680 crates. The Innopal RS<br />
column-type robot stores the supplied<br />
crates. Equipped with additional centering<br />
devices in the head area and holding<br />
devices, it is also able to stack slightly<br />
deformed crates perfectly without any problems.<br />
Shin says, “We are exceedingly satisfied<br />
with <strong>KHS</strong> system technology. In retrospect,<br />
our decision in favor of this highquality<br />
technical solution has proved to be<br />
exactly right.” Hyun-Pal Ha, Managing<br />
Director of the Kumbok-Ju group, adds,<br />
“The efficiency of the line is outstanding.<br />
We are working a two-shift operation at<br />
94-percent efficiency.” And finally Kim,<br />
“It is also of great importance to us that<br />
<strong>KHS</strong> has supplied everything from one<br />
source.” The fire of tradition continues<br />
to burn at Kumbok-Ju.<br />
Rainer Hilgert, Director Business Area<br />
Far East/Australia, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.kumbokju.co.kr<br />
34*35<br />
• CONTACT<br />
Rainer Hilgert, Director Business Area<br />
Far East/Australia, <strong>KHS</strong> AG<br />
Tel: +49/6 71/8 52 – 24 62<br />
E-mail: rainer.hilgert@khs.com<br />
H. W. Kim, President <strong>KHS</strong> South Korea, Seoul<br />
Tel: +82/2/5 18/59 06/8<br />
E-mail: khskorea@kornet.net
Karlsberg Brewery invests in highly flexible <strong>KHS</strong> system technology<br />
MADE TO MEASURE<br />
Karlsberg Brewery had more than half a dozen special requirements for the new filling<br />
line from <strong>KHS</strong>. And major parts of the previous system were to be connected to<br />
it. Order completed to the customer’s satisfaction.<br />
At Karlsberg Brewery, everything concerns the future: “Do today<br />
what others think about tomorrow,” is the motto at the traditional<br />
Homburg-based company, which in the meantime is managed<br />
by the fourth generation of the family. Karlsberg has almost<br />
always gone its own way and has many times shone as an innovation<br />
leader and trendsetter. For instance, it is the only brewery<br />
within the German-French sales region to have been filling beer in<br />
cans since 1953. Or in 1968 when Karlsberg introduced the socalled<br />
giant can to the market. The 3.8-liter and 5-liter size cans<br />
then celebrated gigantic success at the parties of the 1970s.<br />
Today the Karlsberg Brewery is an important nucleus of<br />
the Karlsberg Association, which is active in numerous business<br />
areas. The international multi-channel company provides widely<br />
differing beverages and services well beyond the beer sector – from<br />
fruit juices, soft drinks, and hot beverages through transport and<br />
event services to sandwiches and snacks. The group thus occupies<br />
future-oriented and success-oriented areas on the way from a<br />
regional brewery to internationally successful beverage and service<br />
association.<br />
Regional roots and international alignment are no contradiction<br />
for Karlsberg. “Someone who does not know where he comes<br />
from will not understand where he is going to. Provenance is the<br />
future,” so says Dr. Richard Weber, Managing Partner of Karlsberg<br />
Brauerei KG Weber, on the occasion of the company’s 125-year<br />
anniversary in 2003. Since that year, Karlsberg has been cooperating<br />
with Heineken and Brau Holding International in the domestic<br />
beer sector. Today, the Karlsberg Association ranks among the<br />
top ten beverage manufacturers in Germany. Furthermore, the<br />
Association is the seventh largest export brewery in this country.<br />
CLASSIC AND INNOVATIVE PRODUCT RANGE<br />
New products and containers representing the spirit of the age<br />
are continuously being added to the classic beer range, which<br />
includes Karlsberg UrPils, Gründel´s Alkoholfrei, and Zischke. With<br />
Karlsberg MiXery, the Homburg-based brewery has opened up a<br />
new segment in the beer market. At Karlsberg, mixed beer drinks<br />
have a continuously growing share, currently 20 percent. Dr. Hans-<br />
Georg Eils, Engineering and Logistics Director, puts it in a nutshell:<br />
“For a company that is as innovative as the Karlsberg Brewery,<br />
the technical solutions must of course also be innovative and<br />
flexible to meet the high demands imposed by our quality products.”<br />
It is no wonder that Karlsberg and <strong>KHS</strong> have been working<br />
together on a basis of mutual trust for decades. The latest project<br />
is a new bottling line for glass bottles at the Homburg site that<br />
offers maximum flexibility. The line processes refillable and non-
2<br />
THUMBNAIL PORTRAIT: KARLSBERG<br />
* Founded: 1878<br />
* Location: Homburg<br />
* Collaborations: Heineken, Brau Holding International<br />
* Positioning: One of the top ten beverage manufacturers in<br />
Germany<br />
* Range: Includes Karlsberg UrPils, Gründel’s, MiXery, Desperados<br />
* Philosophy: Do today what others think about tomorrow<br />
refillable bottles for the complete product range and currently<br />
fills refillable 0.33-liter as well as 0.5-liter glass bottles. Capacity:<br />
60,000 bottles per hour. Of course, the line also handles<br />
other sizes of bottle as well as all possible innovative products.<br />
Praise from Tobias Sohns, Bottling Shop Manager at the Karlsberg<br />
Brewery, “The new line exactly meets all our expectations in every<br />
respect.” This also includes a few special tasks, which the company<br />
gave to the <strong>KHS</strong> experts.<br />
TASK 1: MERGE THE OLD AND THE NEW<br />
Among other things, a concept for connecting the existing depalletizer<br />
and palletizer as well as the sorting area to the new line.<br />
Solution: The existing equipment operates in the basement of the<br />
brewery building and the new machinery on the ground floor.<br />
Bottles and crates arrive segregated by type at the Innopack PPZ<br />
decrater located on the ground floor. The Innopack PPZ is extremely<br />
flexible and is outstandingly suitable for use both as a decrater and<br />
as a crater. The logical decision at Karlsberg Brewery was therefore<br />
Innopack PPZ times two. Another modern cyclic crater is there-<br />
task+solution °<br />
fore handles the task of packing filled bottles in prepared crates<br />
at the end of the <strong>KHS</strong> line.<br />
TASK 2: REDUCE CHANGEOVER TIMES<br />
Both Innopack PPZs are fitted with a fully automatic <strong>KHS</strong> format<br />
changing system. At the press of a button, the decrater replaces<br />
the previously used packing head and centering frame with new<br />
components. In addition, the crater controls the fully automatic<br />
lane switching. The only manual intervention required is connecting<br />
and disconnecting the power and air supply hoses. Parking stations<br />
for additional format part sets can be installed later at any<br />
time.<br />
TASK 3: REDUCE BACKGROUND NOISE<br />
Noise reduction wherever feasible – this was the requirement.<br />
<strong>KHS</strong> achieved this not only with the crater and decrater, but also<br />
with all other machines. Special housings are designed so that<br />
the noise-insulating ceiling essentially absorbs the noise.<br />
TASK 4: SAVE SPACE<br />
The Innoclean EE single-end bottle washer saves space versus the<br />
double-end machine and operates with Triple-i-Drive technology.<br />
Another special solution is the crate magazine, which is built directly<br />
onto the pasteurizer. Sohns, “An excellent idea! We have space<br />
for temporarily storing more than 600 crates.”<br />
TASK 5: OPTIMIZE ENERGY CONSUMPTION<br />
The integral patented energy-saving carrier with reduced carrier<br />
36*37<br />
Left Innofill DRS-ZMS: Bottles with low oxygen pick-up, saves CO2 . Center The<br />
Innoclean EE single-end bottle washer, for example, which like all <strong>KHS</strong><br />
machines, has a special noise-insulated housing. Right Container conveyor:<br />
hygienically designed. Large photo right Filling system: Operates with fill level<br />
probes after triple pre-evacuation and double purging with CO2 . Bottom Quickly<br />
relocated from an existing outdated line to the new line: The Innopas C<br />
double-deck pasteurizer with the crate magazine on top to save space.
Karlsberg Brewery invests in highly flexible <strong>KHS</strong> system technology<br />
Left Innopack PPZ: Cog belts for freedom from maintenance and reduced back-<br />
ground noise. Right Praise from Dr. Hans-Georg Eils, Engineering and Logistics<br />
Director (right) and Tobias Sohns, Bottling Shop Manager (center), “The new<br />
<strong>KHS</strong> line is a sophisticated system concept right down to the last detail that<br />
offers plenty of future potential.” Also pictured: Wolfgang Augel, Sales, Germany,<br />
<strong>KHS</strong> AG.<br />
weight permanently reduces energy and fresh water consumptions<br />
and at the same time reduces the heat and caustic carryover<br />
thereby using 10 to 15 percent less heat and 15 to 20 percent less<br />
water.<br />
TASK 6: MAXIMIZE HYGIENE<br />
The bottle washing machine disposes of extracted labels through<br />
a pipe directly into a receptacle provided for this purpose. Maximum<br />
hygiene is the keyword. Hans-Georg Eils, “Modern <strong>KHS</strong> bottle<br />
washing equipment is perfectly in line with our hygiene requirements<br />
and its design is extremely environmentally friendly. Both<br />
aspects are of great importance to the Karlsberg Brewery.”<br />
The line conveys bottles from the bottle washing machine<br />
to the filler over easy-clean conveyors with welded components<br />
(no dirt pockets). The single-lane, hygienically designed container<br />
conveyor is equipped with an integrated interior and exterior sanitizing<br />
system. What is more, incoming and return chains are separated<br />
from one another. Other hygienic components include<br />
special aseptic gear motors to prevent air turbulence.<br />
The microbiological filler front table with its geometrical<br />
shape ensures the selective run-off of product residue, foam, water<br />
and glass fragments out of the biologically critical area of the<br />
filler thereby providing a high degree of microbiological safety.<br />
TASK 7: FLEXIBLE BOTTLING WITH LOW OXYGEN PICK-UP<br />
The Innofill DRS-ZMS computer-controlled pneumatic pressurized<br />
filling system is ideally suited for the low-oxygen bottling of beer<br />
in glass bottles. Furthermore, it is designed for all conceivable fill-<br />
ing situations, whether new bottle shapes and sizes or innovative<br />
beer or mixed beer beverages. Even soft drinks are no problem.<br />
The monoblock filler system currently includes a crown cork capper.<br />
The mechanism for integrating an additional screw capper is<br />
already in place.<br />
TASK 8: INTEGRATE THE EXISTING PASTEURIZER<br />
The Innopas C is a double-deck pasteurizer dating back to 2003<br />
that was previously incorporated in a line, which was to be dismantled<br />
because of its age. The pasteurizer was broken down into individual<br />
modules, transported in sections to the new line where it<br />
was reassembled by <strong>KHS</strong> and modified by adding a section to match<br />
the higher line capacity. <strong>KHS</strong>’ PU control system also makes it<br />
possible to program subsequent product specification changes and<br />
new products at any time.<br />
Director Eils sums up: “The new <strong>KHS</strong> line is a sophisticated<br />
system concept right down to the last detail.” Tobias Sohns adds,<br />
“Regardless of the product consumers may want in the future, we<br />
are already equipped for this today with new <strong>KHS</strong> technology.” Such<br />
as the company’s latest new development: Gründel’s fresh – a<br />
non-alcoholic cocktail of apple and beer. “With Gründel’s fresh,<br />
the Carlsberg Brewery is also applying its innovative strength in<br />
the non-alcoholic beer segment,” comments Alle Ypma, General<br />
Manager of Karlsberg Brewery on this product. It’s looking into<br />
the future that counts.<br />
Günter Unkrig, Director, Central European Business Area, <strong>KHS</strong> AG<br />
Wolfgang Augel, Sales, Germany, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.karlsberg.de<br />
• CONTACT<br />
Günter Unkrig, Director, Central European Business Area,<br />
<strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 16 <strong>02</strong><br />
E-mail: guenter.unkrig@khs.com<br />
Wolfgang Augel, Sales, Germany, <strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 16 35<br />
E-mail: wolfgang.augel@khs.com
task+solution °<br />
The New Belgium Special Brewery in Fort Collins, Colorado brews unique beers and is growing at a<br />
tremendous pace. Although striking and typically American, the history of this young company<br />
began in a basement and not a garage. The partnership between New Belgium and <strong>KHS</strong> is also<br />
developing extremely dynamically with a new filling line that is unexcelled in the United States.<br />
During a bike trip through Europe on his<br />
old-fashioned bicycle, Jeff Lebesch had no<br />
idea that his life was about to change dramatically.<br />
For after returning home, the<br />
electrical engineer from Fort Collins, Colorado<br />
began brewing beer in his basement<br />
in the finest Belgian tradition that he had<br />
learned to love during his bike trip. Both<br />
of his first two creations, Abbey and Fat<br />
Tire, quickly earned a reputation among<br />
family and friends for their remarkable and<br />
well-balanced taste. People were now<br />
drinking delicious Belgian beer in a form<br />
that could otherwise only be enjoyed<br />
abroad.<br />
Together with his wife, Kim Jordan,<br />
Lebesch gradually expanded the brewing<br />
activities in his basement and officially<br />
opened for business in 1991. Kim took care<br />
of marketing and sales and even delivered<br />
beer herself in the family station wagon.<br />
In 1995, the team expanded further and<br />
moved to a railroad depot. But they soon<br />
outgrew this second location and consequently<br />
the built their first real brewery<br />
shortly thereafter. Today, the New Belgium<br />
Brewery with headquarters in Fort Collins,<br />
Colorado is the third largest specialist brewery<br />
in America and has a whole line of<br />
unique beers in its assortment of products.<br />
38*39<br />
STRONG<br />
PARTNERS<br />
New Belgium Brewery in Colorado<br />
places trust in <strong>KHS</strong>
2<br />
THUMBNAIL PORTRAIT: NEW BELGIUM<br />
* Founded: 1991<br />
* Headquarters: Fort Collins, Colorado, U.S.A.<br />
* Positioning: Third largest specialist brewery in<br />
the United States. Owner managed.<br />
* Sales: 476,100 beer barrels (@ 31 U.S. gallons)<br />
It is fantastic how sales of 476,100 beer<br />
barrels (@ 31 U.S. gallons) have developed<br />
from an experiment in the basement. What<br />
is more, Jeff Lebesch is expecting a further<br />
9-percent increase in production for<br />
the current year. And so to the equipment.<br />
New Belgium’s earlier systems consisted of<br />
two filling lines with a capacity of 300 bottles<br />
per minute and 120 half-barrel kegs<br />
(@ 15.5 U.S. gallons) per hour. The company<br />
then introduced a new organic beer<br />
(Mothership Wit) and as a result of substantial<br />
growth rates was forced to make<br />
further investments in the plant in order<br />
to keep everything up and running.<br />
THE SEARCH FOR THE RIGHT PARTNER …<br />
First of all, the management put together<br />
basic criteria and building specifications<br />
for the construction of a new filling and<br />
packing shop. Discussions were then held<br />
with five possible suppliers with particular<br />
attention being paid to maintenance,<br />
operational procedures, and engineering.<br />
When making their assessment, New Belgium<br />
placed particular emphasis on the following<br />
items:<br />
* Customer service<br />
* Availability of parts and support<br />
* State of the art<br />
* Services<br />
* Customer satisfaction and training<br />
* Reputation in the brewing industry<br />
… LEADS TO <strong>KHS</strong> …<br />
The decision was made quickly and clearly.<br />
<strong>KHS</strong> <strong>US</strong>A based in Waukesha, Wisconsin was<br />
the first choice. “<strong>KHS</strong> scored well with<br />
regard to engineering, technology, and<br />
innovation, and has an outstanding reputation<br />
in the brewing industry,” summarizes<br />
Jim Spencer, New Belgium’s Engineering<br />
Director. With the latest technology,<br />
<strong>KHS</strong> was able to come up with exactly what<br />
the company required. “Innovation has<br />
always been valued highly by the company<br />
founders, Jeff and Kim,” explains Spencer,<br />
“and <strong>KHS</strong> is absolutely in the lead as far<br />
as technology is concerned.”<br />
… AND TECHNOLOGY PREVIO<strong>US</strong>LY<br />
UNKNOWN IN THE U.S.A. …<br />
<strong>KHS</strong> has provided New Belgium with technology<br />
that until now was unknown in the<br />
U.S. (including a new bottling machine, a<br />
wrap-around packer, and a robot palletizer),<br />
which in the meantime is in operation at
the new production plant (total area over<br />
5,000 square meters). The plant expansion<br />
with an investment volume of at least<br />
20 million <strong>US</strong> dollars includes numerous<br />
environmentally friendly design elements<br />
and technologies, one example of which is<br />
the <strong>KHS</strong> filler with reduced CO 2 consumption.<br />
… WITH FOC<strong>US</strong> ON FILLING …<br />
The electronic Innofill DRS-ZMS filler – an<br />
innovation in the U.S. brewing industry –<br />
made a particularly strong impression on<br />
the New Belgium employees. Like most of<br />
the European beer manufacturers, New Belgium<br />
retains the quality of its beers by<br />
not pasteurizing them. Filling valves with<br />
probes are used in the <strong>KHS</strong> filler to guarantee<br />
exact fill levels and minimize the<br />
oxygen pick-up in the bottle during filling.<br />
Low oxygen content protects the flavor of<br />
the beer and increases the shelf life.<br />
“The filler improves fill level accuracy<br />
and CO 2 and water consumption,”<br />
praises Spencer. “It provides high flexibility<br />
for product changes, and we are all<br />
extremely impressed by the technology and<br />
each of the structural elements.” New Belgium’s<br />
previous bottling line operated at<br />
an output of 300 bottles per minute. The<br />
new <strong>KHS</strong> filler has increased the capacity<br />
of the bottling plant to more than 700 bottles<br />
per minute. The brewery now has a<br />
capacity of 850,000 beer barrels per year.<br />
… AND THE LATEST PACKAGING …<br />
Perfection is also the name of the game<br />
when it comes to packaging. The new <strong>KHS</strong><br />
Innopack Kisters WP wrap-around packer<br />
is an innovation in the U.S.A. and exactly<br />
matches New Belgium’s efficient and flexible<br />
packaging line. “The machine provides<br />
an innovative solution for packing bottles,”<br />
explains Spencer. “At the same time, the<br />
task+solution ° New Belgium Brewery places trust in <strong>KHS</strong><br />
Left View of the bottling shop: Investment volume of 20 million <strong>US</strong> dollars. Top The filler: Precise filling<br />
accuracy and minimized oxygen levels for optimum beer flavor and longer shelf life. Bottom Wrap-around<br />
packer: With partition inserter – an innovation in the U.S.A.<br />
<strong>KHS</strong> solution takes up less space, provides<br />
higher efficiency, and is very attractive<br />
overall”.<br />
In the past, the brewery purchased premade<br />
cartons. The new system produces<br />
cartons directly from cardboard blanks while<br />
the bottles are being packed. At the same<br />
time, the cartoner erects the partitions<br />
then aligns and slides them between the<br />
bottles. It then folds the carton, wraps it<br />
around the bottles, and applies adhesive<br />
to an inside flap.<br />
… AND PERFECT LABELS …<br />
The <strong>KHS</strong> Innoket KL cold glue labeling<br />
machine now enables New Belgium to apply<br />
back labels to the bottles as well. “A back<br />
label is a special way of attracting the consumer’s<br />
attention to the product,” Spencer<br />
asserts. Throughput has increased to over<br />
800 bottles per minute while labels with a<br />
length of up to 170 mm can be applied to<br />
the front of the bottle.<br />
… AND THE MOST FLEXIBLE ROBOT<br />
TECHNOLOGY<br />
The <strong>KHS</strong> palletizer robot also delighted New<br />
Belgium with its capabilities of handling<br />
widely differing designs of container and<br />
pallet layouts. The robot arm, another first<br />
for the States, aligns the containers in layers,<br />
and stacks them on top of each other.<br />
The wrapped packs go straight from the<br />
palletizer to the waiting truck. This system<br />
makes palletizing more precise and<br />
reduces the work effort.<br />
THE SUCCESS STORY CAN CONTINUE<br />
New Belgium chose <strong>KHS</strong> as a partner not<br />
only because of the highly sophisticated<br />
equipment and future-oriented technology,<br />
but also above all because the company<br />
values greatly the high motivation<br />
and dedication of <strong>KHS</strong>’ staff. “Ultimately,<br />
2<br />
what tipped the balance in <strong>KHS</strong>’ favor was<br />
the support that we could expect from <strong>KHS</strong>,”<br />
recalls Spencer, and praises, “we are highly<br />
impressed with the commitment during our<br />
ongoing collaboration and partnership.”<br />
Furthermore, the <strong>KHS</strong> team obviously also<br />
made an impression during commissioning.<br />
Spencer sees it this way: “During this<br />
phase, <strong>KHS</strong> spared no effort to ensure that<br />
the system worked as quickly as possible<br />
in accordance with our requirements.” His<br />
summary in brief: “<strong>KHS</strong> showed great commitment<br />
and great dedication.”<br />
During the acceptance tests, the<br />
new line ran with an average efficiency of<br />
98 percent and therefore noticeably<br />
exceeded New Belgium’s expectations.<br />
There is hardly any doubt that the new line<br />
will quickly reach the strived return on<br />
investment. What a strong partnership.<br />
Colby McLean, Western Regional Sales Manager,<br />
<strong>KHS</strong> <strong>US</strong>A, Inc.<br />
fi<br />
THE ABCS OF BARRELS<br />
INFOBOX<br />
40*41<br />
* One beer barrel equals 31 U.S. gallons<br />
* One half beer barrel equals 15.5 U.S. gallons<br />
* A <strong>US</strong> gallon equals 3.785411784 liters<br />
• WEBSITE www.newbelgium.com<br />
• CONTACT<br />
Colby McLean, Western Regional Sales Manager<br />
<strong>KHS</strong> <strong>US</strong>A, Inc.<br />
Tel: +01/425 – 522 – 4215<br />
E-mail: colby.mclean@khs.com
The German Kulmbacher Brauerei AG is undoubtedly a company steeped in tradition<br />
that understands the art of brewing. The Group has been pursuing an exemplary<br />
strategy for a long time, focusing on values such as quality and resource conservation.<br />
A new filling and packaging line from <strong>KHS</strong> with several innovative features fits the bill.
The first sight visitors to Kulmbach in Upper<br />
Franconia, Germany, will see is the picturesque<br />
Plassenburg. Other prominent<br />
features of the townscape include the hoods<br />
of the malt drying kilns, brewery buildings,<br />
hotels, and restaurants. It has been like<br />
this for as long as anyone can remember,<br />
because beer has always had a strong influence<br />
on the life of the people in this region.<br />
Kulmbach Bierwoche is an annual event<br />
that starts on the last weekend in July.<br />
Two numbers indicate the significance of<br />
the event: Population: 30,000, visitors:<br />
120,000.<br />
And finally, a 3,000-year-old beer<br />
amphora was discovered some time ago in<br />
the “secret beer capital” as the oldest evidence<br />
of the German art of brewing. There<br />
is strength in unity. On this note, the<br />
previously independent breweries Reichelbräu,<br />
Sandlerbräu, Mönchshof, and EKU<br />
joined forces under the name of Kulmbacher<br />
Brauerei AG back in 1996. The Group also<br />
includes the traditional breweries Sternquell<br />
and Braustolz in Saxony, Würzburger<br />
Hofbräu, Scherdel, Hof, and the non-alcoholic<br />
division of Bad Brambacher Mineralquellen.<br />
UNIQUE PRODUCT RANGE …<br />
Accordingly, the Group offers a wide range<br />
of no less than 28 styles of beer, including<br />
famous brands such as<br />
* Kulmbacher – national premium brand<br />
with a leading role in northern Bavaria.<br />
The group’s best selling product is Kulmbacher<br />
Edelherb, a full-bodied, palatable<br />
Pils.<br />
* EKU – for traditional beer connoisseurs.<br />
* Mönchshof – small, fine specialty,<br />
undisputed top seller among clip-lock<br />
bottles in Bavaria and nationally well<br />
on its way to becoming number one.<br />
* Kapuziner Weissbier – the number two<br />
task+solution °<br />
Kulmbacher Brewery: Focus on quality and environment<br />
The Beer Experts<br />
Left High-performance-line: fills up to 50,000 bottles per hour. Top Innopal PE: Depalletizes<br />
empties crates layer by layer. Right Innovative bottle infeed for single-end Innoclean EE bottle<br />
washer: The bottles enter the machine with minimum pressure and noise over smooth<br />
pushover points. Openings in the conveyors ensure broken glass is discharged properly.<br />
in northern Bavaria. Among the top<br />
ten wheat beers in Germany.<br />
The company uses an elaborate three-tank<br />
beer production process. All beer ingredients<br />
come from – who could expect otherwise<br />
– the region.<br />
Around 80% of all products are sold<br />
in glass bottles (mainly refillable), around<br />
20% in kegs and a small proportion in cans.<br />
The range of bottle types and sizes used<br />
includes traditional brown glass bottles<br />
and clear glass bottles in 0.33 and 0.5-liter<br />
sizes and all common bottle shapes including<br />
NRW, long neck and clip-lock.<br />
… IS THE BASIS FOR SUCCESS<br />
During the 2007 financial year, the Kulmbacher<br />
Group achieved a total output of<br />
3.6 million hectoliters (2.4 million hectoliters<br />
of beer and 1.2 million hectoliters<br />
of non-alcoholic beverages). Sales totaled<br />
223.5 million euros.<br />
Experts honor the fact that quality<br />
is a fundamental pillar of the corporate<br />
strategy, covering all aspects of the Group’s<br />
activities. At the recent 20<strong>08</strong> DLG Beer<br />
Test, for example, all seven beers submitted<br />
by Kulmbacher were awarded gold<br />
medals. This was a strong endorsement for<br />
the brewmasters and illustrated that continuous<br />
investments in quality benefit consumers.<br />
The company has long since been<br />
active outside its core market. Kulmbacher<br />
42*43
2<br />
THUMBNAIL PORTRAIT: KULMBACHER BREWERY<br />
* Founded: 1846<br />
* Structure: Merger (1996) of Reichelbräu, Sandlerbräu, Mönchshof und<br />
EKU. Further companies: Sternquell, Braustolz, Würzburger Hofbräu,<br />
Brauerei Scherdel, Bad Brambacher Mineralquellen<br />
* Beer brands: Kulmbacher, EKU, Mönchshof, Kapuziner Weissbier (a total of<br />
28 styles of beer)<br />
* Output 2007: 3.6 million hectoliters (of which two-thirds is beer)<br />
* Sales 2007: 223 million euros<br />
beer has been popular in central and northern<br />
Germany and abroad for more than 150<br />
years. In 1900, the company already<br />
exported 733,000 hectoliters of beer.<br />
Today, brand name beers are represented<br />
particularly strongly in Italy and France;<br />
EKU traditionally also in Asia. “EKU is<br />
well known in Asia. Like all Kulmbacher<br />
brand name beers, it conveys a feeling of<br />
Bavarian life to consumers,” says Dr. Helga<br />
Metzel, Director of Corporate Communications.<br />
THE SPECIAL FEATURES OF THE<br />
<strong>KHS</strong> LINE<br />
The new high-performance filling and packaging<br />
line with a capacity of 50,000 bot-<br />
tles per hour processes 0.33 and 0.5 liter<br />
glass bottles and is used for a wide range<br />
of Kulmbacher beer varieties. Kulmbacher<br />
decided to use <strong>KHS</strong> as turnkey supplier,<br />
because <strong>KHS</strong> equipment meets the demand<br />
for flexibility while taking into account<br />
environmental aspects and offering perfect<br />
filling and quality results. In addition,<br />
the line design is top of the range when it<br />
comes to hygiene. The special line characteristics<br />
in terms of energy and environment<br />
are described below.<br />
* Heat consumers such as the bottle<br />
washer and the process equipment are<br />
fully insulated. This reduces the energy<br />
consumption significantly.<br />
* The bottle washer was designed for max-<br />
Conveyors: Easy clean design meets maximum demands.<br />
imum energy efficiency. A unique innovative<br />
feature the Kulmbacher brewmasters<br />
came up with is to use natural gas<br />
as heat source. This saves energy costs<br />
and reduces CO 2 emissions.<br />
* At the infeed of the single-end Innoclean<br />
EE bottle washer, the chains are<br />
routed to ensure that the bottles enter<br />
the machine with minimum pressure<br />
and noise. Upstream of the main caustic<br />
bath, the bottles are presoaked and<br />
sprayed under high-pressure. The labels<br />
are thus largely removed before the<br />
main caustic bath, resulting in reduced<br />
contamination of the main caustic bath<br />
and lower chemical consumption.<br />
* The energy-saving bottle carriers used
to convey the bottles through the<br />
machine save 10 to 15% heat and 15<br />
to 20% water.<br />
* The control system automatically<br />
switches off empty conveyors thereby<br />
reducing the power consumption<br />
noticeably.<br />
* The PMS Plant Information System from<br />
<strong>KHS</strong> is based on the latest Weihenstephan<br />
standard and makes consumption<br />
data, quality, process sequences,<br />
and cost structures transparent. Intervention<br />
into the ongoing process is possible<br />
at all times. In the long term,<br />
this protects resources and ensures that<br />
the line, which, incidentally, is connected<br />
to the <strong>KHS</strong> Remote Diagnostic<br />
Service (ReDiS), operates efficiently.<br />
* The filler area is located in a separate<br />
room, which is under positive pressure<br />
and is continuously supplied with<br />
filtered air.<br />
* Equipped with 144 filling stations, the<br />
highly versatile Innofill DRS-ZMS filling<br />
system ensures top beer quality<br />
with its extremely low-oxygen filling<br />
process coupled with low CO 2 consumption.<br />
* The easy-clean conveyors require little<br />
maintenance.<br />
* The infeed and outfeed conveyor at the<br />
single-lane filler is designed based on<br />
task+solution ° Kulmbacher Brewery: Focus on quality and environment<br />
strict hygiene standards (housing with<br />
raised slide strips, incoming and returning<br />
chains are separated). Advantage:<br />
This allows any product residue to drain<br />
off at the side. The returning chain is<br />
not exposed to overflowing product.<br />
Other features include a microbiologically<br />
beneficial filler front table with<br />
controlled and fast drain-off of all product<br />
residue, foam, and water.<br />
* Special <strong>KHS</strong> buffer systems are integrated<br />
between individual machines.<br />
Optimum decoupling of the individual<br />
units saves space and improves system<br />
efficiency.<br />
* Two Innopack PPZ double-axis gantry<br />
robots for packing and unpacking are<br />
equipped with the fully automatic <strong>KHS</strong><br />
format changing system that requires<br />
fewer resources during changeover.<br />
* The Innopal RS 3 palletizer features a<br />
gripper head and is able to compensate<br />
differences in crate dimensions.<br />
This results in perfect layer patterns,<br />
gentle product handling and high overall<br />
stability of the pallet load.<br />
Stefan Simon, Director of Production Engineering<br />
at Kulmbacher Brewery, sums it<br />
up: “The line features sophisticated design<br />
details that enable us to offer our consumers<br />
exactly the quality they ask for.<br />
Left Innoclean EE with environment-friendly gas<br />
heating for reduced energy costs and CO 2 emissions.<br />
Center Innopack PPZ: Crater and decrater with fully<br />
automatic format changeover system. Right Innopal<br />
RS 3: Palletizes filled crates and at the same time<br />
manages palletizing of excess empty crates.<br />
In addition, it meets the high environmental<br />
standards laid down by Kulmbacher<br />
Brewery.” After all, beer is everything in<br />
this region.<br />
Günter Unkrig, Director,<br />
Central European Business Area, <strong>KHS</strong> AG<br />
Frank Fretwurst,<br />
Sales Manager, Southern Germany, <strong>KHS</strong> AG<br />
Frank Schneidermann,<br />
Sales, Germany, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.kulmbacher.de<br />
• CONTACT<br />
Günter Unkrig, Director, Central European<br />
Business Area, <strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 16 <strong>02</strong><br />
E-mail: guenter.unkrig@khs.com<br />
Frank Fretwurst, Sales Manager,<br />
Southern Germany, <strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 17 96<br />
E-mail: frank.fretwurst@khs.com<br />
Frank Schneidermann, Sales, Germany,<br />
<strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 11 04<br />
E-mail: frank.schneidermann@khs.com<br />
44*45
Hacklberg Brewery combines tradition with innovation<br />
Firm Roots<br />
Since 1618, the Hacklberg Brewery has supplied the Lower Bavarian countryside around Passau<br />
with high-quality beer. While many brewing operations have recently suffered sales losses,<br />
the cult brand of Hacklberg is doing fine. For this line of 42 products, <strong>KHS</strong> is now providing<br />
highly flexible system technology.<br />
This is real tradition: The Thirty Years’ War<br />
– in 1618 to be exact – was the time when<br />
beer was first brewed at the Hacklberg Brewery<br />
in the prince-bishopric of Passau. In<br />
the 19th century, the company became property<br />
of the Elector, advancing to the status<br />
of royal brewery. Soon thereafter, private<br />
parties purchased the operation, but in 1897,<br />
it reentered the ownership of the church.<br />
Stephan Marold, Director of the brewery,<br />
puts it this way, “Within the region, Hacklberg<br />
is sometimes compared to a well-rooted<br />
2<br />
THUMBNAIL PORTRAIT: HACKLBERG<br />
* Founded: 1618<br />
* Turnover: 300,000 hl<br />
* Product range: 42 styles of beer and soft drink<br />
* Production: 180,000 hl of beer, 120,000 hl<br />
of soft drinks<br />
oak. People say, Everything changes, except<br />
one thing – Hacklberg.”<br />
According to Marold, that continues<br />
to bring security and substantiality, as<br />
well as a successful combination of the traditional<br />
and the modern. “The decisive point<br />
for what we do is our need for high quality,”<br />
says Marold. And customers reward<br />
that with consistent brand loyalty. The company<br />
has a distribution share of 90% in the<br />
brewery’s core market, which is within a<br />
radius of about 70 kilometers.<br />
LEADER IN LOWER BAVARIA<br />
With a production of 300,000 hectoliters<br />
per year, the brewery is currently number<br />
two in Lower Bavaria (in 2007, 180,000 hectoliters<br />
of beer and 120,000 hectoliters of<br />
soft drinks). But while many Bavarian breweries<br />
have suffered sales losses in the past<br />
few years, Hacklberg has stood its ground<br />
with regard to beer sales. The company<br />
offers three brands of soft drinks: Sonnenland,<br />
Frizz, and Dachsbergquelle. The Sonnenland<br />
line includes a total of 14 different<br />
products. The top-selling soft drink is<br />
a cola mix, with a 40% share of sales followed<br />
by orange soda pop, apple spritzer,<br />
and table water.<br />
In all, the product line includes 42<br />
different styles of beer and soft drinks. The<br />
company fills this broad spectrum of products<br />
with a wide variety of bottle types in<br />
eight returnable glass bottles, ranging from<br />
the classical 0.5-liter NRW and 0.33-liter
longneck bottles for beer, to the 0.7-liter<br />
GDB and the 0.75- and 0.25-liter gourmet<br />
bottle for soft drinks.<br />
FLEXIBLE NEW SYSTEM TECHNOLOGY<br />
FROM <strong>KHS</strong><br />
Recently, the brewery invested in new bottle<br />
washing, filling, and blending technology.<br />
Their trusted supplier was <strong>KHS</strong>.<br />
Stephan Marold says, “Our experience with<br />
<strong>KHS</strong> has been very good in the past. For<br />
the main components of the new line, there<br />
was just no getting past <strong>KHS</strong> quality again.”<br />
The location of the new filling and<br />
packaging line is Hutthurm, only a few kilometers<br />
away from Passau. There, in 1998,<br />
after only six months of construction, the<br />
Hacklberger Beverage and Logistics Center<br />
(HGL) was built. To date, four filling and<br />
packaging lines in three locations have been<br />
delivering to this logistics center. With this<br />
new line, which is replacing all existing lines,<br />
both the logistic center and the filling and<br />
packaging technology are now centrally<br />
located in Hutthurm. However, the brewery<br />
will continue to remain loyal to the Passauer<br />
neighborhood of Hacklberg. Marold<br />
says that this is mainly because that is where<br />
the company’s roots lie.<br />
With this variety of products and bottles,<br />
the new system technology must be especially<br />
flexible. That starts with the <strong>KHS</strong><br />
Innopro PARAMIX CMX blending system,<br />
expanded with additional dosing segments.<br />
Supplying beer and thus blending beer mixed<br />
beverages inline is just as easy as dosing<br />
minimal amounts of flavoring or other additives.<br />
The dosing accuracy for syrup is about<br />
0.05° Brix, and for CO 2 it is approx. 0.2 g<br />
of CO 2 per liter. All product data is stored<br />
in recipe memory ready for retrieval by the<br />
operating crew at the push of a button.<br />
The computer-controlled pneumatic<br />
Innofill DRS-ZMS pressure filling system<br />
has 1<strong>08</strong> filling stations and processes<br />
up to 40,000 0.5-liter bottles per hour. There<br />
is both a crown corker for beer and a screw<br />
capper for non-alcoholic beverages. A microbiological<br />
filler front table, optimized bottle<br />
guide parts, and hygienically designed<br />
filling valves ensure sanitary conditions in<br />
the filling area. The glass enclosure for<br />
the filler / capper area provides maximum<br />
transparency. The system is driven by the<br />
latest in servo technology.<br />
Director Marold is full of praise, “The<br />
<strong>KHS</strong> filling concept is convincing right down<br />
the line including the so very essential low-<br />
task+solution °<br />
Left/center Innoclean EE: Stainless is the key. Top The computer-controlled, pneumatic pressure filling system Innofill DRS-ZMS stands for a gen-<br />
tle, low-oxygen filling process. Bottom Stephan Marold, Director of the Hacklberg Brewery (right): “Our experience with <strong>KHS</strong> has been very good<br />
in the past. Once again, we just couldn’t pass up <strong>KHS</strong> quality when it came to the hearts of the new line.” Also pictured: Frank Fretwurst, Marketing<br />
Manager, Southern Germany, <strong>KHS</strong> AG.<br />
oxygen filling process. At the same time,<br />
we’re talking about the extremely hygienic<br />
design, a high degree of user friendliness,<br />
short changeover times, and maximum flexibility.”<br />
The fully insulated Innoclean EE<br />
bottle washer made entirely of stainless<br />
steel is equally compelling. Marold says,<br />
“That increases the service life and together<br />
with the energy-saving carriers, minimizes<br />
power consumption.” And with Triple-i-Drive<br />
technology, the widest variety of bottle<br />
shapes and sizes can be processed with the<br />
shortest of changeover times. Marold says,<br />
“With the new <strong>KHS</strong> bottle washer, positive<br />
aspects go hand in hand, mutually reinforcing<br />
each other. In comparison with the bottle<br />
washing equipment we have used in the<br />
past, we’re referring to 30% lower water<br />
consumption. And power savings are similar.”<br />
From the region, for the region –<br />
and always following the motto that the<br />
Hacklberg Brewery has always called its own:<br />
Reliability earns customers.<br />
Günter Unkrig, Director,<br />
Central European Business Area, <strong>KHS</strong> AG<br />
Frank Fretwurst, Sales Manager,<br />
Southern Germany, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.hacklberg.de<br />
• CONTACT<br />
Günter Unkrig, Director, Central<br />
European Business Area, <strong>KHS</strong> AG,<br />
Dortmund<br />
Tel: +49/2 31/5 69 – 16 <strong>02</strong><br />
E-mail: guenter.unkrig@khs.com<br />
Frank Fretwurst, Sales Manager,<br />
Southern Germany, <strong>KHS</strong> AG, Dortmund<br />
Tel: +49/2 31/5 69 – 17 96<br />
E-mail: frank.fretwurst@khs.com<br />
46*47
Innofill NRS: Worldwide new principle for bottling convenience drinks<br />
Focus on Wellness<br />
The new <strong>KHS</strong> Innofill NRS processes small plastic containers for non-carbonated<br />
products, hot or cold, without the use of lifting elements. What advantages<br />
does this have and what else does the technology have to offer?<br />
Top Innofill NRS: Processes a comprehen-<br />
sive product range. Bottom After filling,<br />
optimized capping: Different alternatives<br />
for snacks in plastic containers with<br />
aluminum cap or classical screw cap<br />
Health and correspondingly oriented convenience<br />
drinks are the major trend of the<br />
time. Consumers are increasingly questioning<br />
how carefully or hygienically the product<br />
has been processed. Manufacturers must<br />
meet these requirements – but at the same<br />
time, they want simple and economically<br />
optimized filling systems. Problem solved,<br />
the new Innofill NRS from <strong>KHS</strong> focuses very<br />
specifically on filling small plastic containers<br />
with non-carbonated products using<br />
a worldwide new principle, which involves<br />
less wear and therefore provides higher availability.<br />
But more of that later. First a few<br />
important parameters relating to the use of<br />
the filling system.<br />
WIDE PRODUCT RANGE<br />
The consumer demands variety. As a computer-controlled<br />
isobarometric pressure probe<br />
filler, the Innofill NRS processes a comprehensive<br />
product range: classical and viscous<br />
juice drinks, juice-vegetable or pure vegetable<br />
drinks or mixed dairy products with cereals<br />
and much more. The basic principle: The system<br />
fills everything that is flowable.<br />
LIGHTWEIGHT CONTAINERS<br />
The consumer demands convenient containers.<br />
For this reason, the Innofill NRS is particularly<br />
designed for the flexible filling of<br />
lightweight plastic containers in a variety<br />
of sizes and shapes. Such containers for<br />
between-meal snacks usually vary between<br />
100 and 500 milliliters. Of course, somewhat<br />
smaller or slightly larger containers<br />
can also be filled. The basic principle: The<br />
system flexibly adapts to the customers’<br />
requirements.<br />
WIDE MOUTHS<br />
The consumer wants convenience. The<br />
Innofill NRS fills containers with mouth<br />
diameters of at least 20 millimeters. The<br />
basic principle: Due to larger mouths, the<br />
system above all allows convenient and rapid<br />
consumption of highly viscous products.<br />
THE 10 TECHNOLOGICAL ADVANTAGES<br />
1 Filling without lifting elements<br />
A world innovation: With the Innofill NRS,<br />
the filling level probe only lowers fully automatically<br />
into the container once it is positioned<br />
directly below the filling valve. This<br />
has never before been the case in this form.<br />
2 Non-contact filling<br />
When the container has been positioned<br />
in the neck ring holder and below the filling<br />
valve, the filling valve opens and the<br />
probe moves fully automatically into the<br />
container. Non-contact filling using the<br />
free-flow principle provides microbiological<br />
safety – there is no longer a need to<br />
press and seal the container mouth against<br />
the filling valve.
7 Filling with optimum hygiene<br />
From ring bowl to filling valve – smooth<br />
paths everywhere with aseptic membrane<br />
and sealing technology within the filling<br />
valves and for all product-conducting channels<br />
and paths.<br />
8 Filling with simplest possible<br />
cleaning<br />
CIP sanitizing is simple and extremely<br />
hygienic. Rinsing pans are positioned underneath<br />
the filling valves for CIP circulation.<br />
Cleaning media enter the ring bowl. From<br />
here, they pass through the intended CIP<br />
channels before entering the rinsing bowl<br />
through the free-flow filling valves. Finally,<br />
the cleaning media are returned to the cleaning<br />
media tank through the circulation pump<br />
and the catchment tank.<br />
technology+innovation °<br />
3 Filling with uniform fill levels<br />
5 Non-drip filling<br />
9 Hot or cold filling<br />
The filling valve closes as soon as the fill- Single-stage or two-stage: both must be The Innofill NRS is intended for hot filling.<br />
ing level touches the tip of the probe. The drip-free. This is ensured by a gas lock in However, non-carbonated products can also<br />
probe moves fully automatically out of the the product outlet. This also allows a defined be processed cold.<br />
container. This ensures uniform fill levels. proportion of solids to pass through, which<br />
is decisive with products containing fruit 10 Filling with infeed plate<br />
4 Filling in one or two stages pulp or cereals.<br />
The system guides the containers over an<br />
The single-stage filling process is common<br />
infeed plate that has no format parts, into<br />
for smaller containers. Two-stage filling is 6 Filling with return flow<br />
the rinser-filler-capper monoblock where it<br />
possible with the Innofill NRS depending The filling valves are connected to a par- passes them on accordingly after each sta-<br />
on the product and the container used. The tially filled ring bowl. If the line should tion. Focus on simplicity.<br />
second stage is recommended for large-vol- come to a stop, the heated product circu- Optimized capping follows filling.<br />
ume containers, particularly when foamlates through the ring bowl.<br />
Here, <strong>KHS</strong> offers various alternatives. Both<br />
ing occurs: fast fill phase in the cylindrical<br />
the aluminum cap and the classical screw<br />
part and then low-foam slow fill phase in<br />
cap are possible for snacks in plastic con-<br />
the narrower container neck.<br />
tainers.<br />
fi<br />
INFOBOX<br />
• WEBSITE www.khs.com<br />
• CONTACT<br />
Ludwig Clüsserath, Manager, Process<br />
Engineering Competence Center,<br />
<strong>KHS</strong> AG, Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 25 01<br />
E-mail: ludwig.cluesserath@khs.com<br />
Walter Senft, Manager,<br />
Wine, Champagne, Juice and Spirit<br />
System Sales, <strong>KHS</strong> AG, Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 23 80<br />
E-mail: walter.senft@khs.com<br />
The bottom line: With the Innofill NRS, <strong>KHS</strong><br />
provides a filling system that not only fulfils<br />
the demands of the market, but also<br />
goes a long way toward satisfying future<br />
requirements. The system gives the beverage<br />
and food industries the opportunity of<br />
(further) pursuing the health and convenience<br />
trend consistently and objectively.<br />
Ludwig Clüsserath, Manager, Process Engineering<br />
Competence Center, <strong>KHS</strong> AG<br />
Walter Senft, Manager, Wine, Champagne,<br />
Juice and Spirit System Sales, <strong>KHS</strong> AG<br />
48*49<br />
Left Filler specialty: Small plastic containers with non-<br />
carbonated products. Right Filler range: Classical vis-<br />
cous juice, juice-vegetable or pure vegetable or mixed<br />
milk drinks with cereals – and much, much more.
For non-alcoholic beverages: Now integrated hot-fill version for PET<br />
Hot Stuff<br />
Hot filling – like aseptic cold filling with isolator<br />
technology – also provides microbiological safety<br />
for non-alcoholic beverages in plastic bottles.<br />
As a trendsetter, <strong>KHS</strong> provides innovative hot-fill<br />
versions that leave simply nothing to be desired.<br />
This is the future: The trade is more and<br />
more frequently wanting to hot-fill microbiologically<br />
sensitive non-alcoholic beverages<br />
in plastic bottles. The reason is that,<br />
in this way, clean room equipment and significantly<br />
increasing hygiene management<br />
can be avoided, even if the costs associated<br />
with hot filling are higher. At the same time,<br />
the trade basically wants simple filling systems<br />
that are tailored highly flexibly to<br />
the ever-wider variety of products. Problem<br />
solved: The <strong>KHS</strong> DRV-VF/NH is here – a<br />
system that fills hot or cold, processes carbonated<br />
as well as non-carbonated beverages<br />
with different degrees of sensitivity,<br />
and can be operated with or without pres-<br />
sure. But for orientation, first a brief glance<br />
at the family of Innofill DRV fillers from <strong>KHS</strong>,<br />
all of which are the latest computer-controlled<br />
volumetric systems with the major<br />
advantage of simple control concepts.<br />
* Version 1: DRV-VF exclusively bottles<br />
carbonated soft drinks and water. Only<br />
two pneumatic functions control the<br />
entire filling process – including the<br />
lifting operation and sealing the bottle<br />
mouth against the filling valve.<br />
* Version 2: DRV-VF/N allows the pressurized<br />
filling of carbonated soft drinks<br />
and the pressureless filling of still water<br />
and similar products. A further control<br />
function is included, which quite<br />
simply manages the operating mode<br />
changeover from pressurized filling to<br />
pressureless filling for all filling valves<br />
in a machine at the same time.<br />
* Version 3: DRV-VF/DN additionally provides<br />
the option of always pressurizing<br />
more microbiologically sensitive carbonated<br />
refreshers, such as apple spritzer,<br />
with freshly filtered gas using the triplechamber<br />
process. The system then also<br />
works with a high proportion of inert<br />
gas when filling thereby reducing the<br />
oxygen pickup. The changeover from<br />
classical pressurized filling using the<br />
single-chamber principle to triple-chamber<br />
pressurized filling for carbonated<br />
beverages and also the pressureless<br />
mode of operation is achieved at the<br />
push of a button.<br />
* Version 4: DRV-VF/NH, which along with<br />
single-chamber pressurized filling and<br />
pressureless cold filling, now also allows<br />
hot filling.<br />
The following contains a summary of possible<br />
future frequently asked questions about<br />
the Innofill DRV-VF/NH.<br />
HOW MUCH EFFORT IS INVOLVED IN<br />
CHANGEOVER?<br />
All filling valves can be changed over from<br />
pressurized to hot filling at the push of a
Left Innofill DRV-VF/NH for PET: Bottles carbonated and non-carbonated bever-<br />
ages under pressure and pressureless cold and hot. Right Innofill NV-H for<br />
PET: Bottles only non-carbonated, non-alcoholic beverages cold or hot.<br />
button by means of pilot valves. A likewise<br />
centrally controlled membrane cylinder triggers<br />
the beverage circulation within the<br />
filling valves in standstill phases during<br />
hot filling. In the case of a filler with 100<br />
filling stations, this type of control saves<br />
up to 297 solenoid valves, which reduces<br />
the complexity with potential savings in<br />
service and maintenance. The operator<br />
selects the required operating mode at the<br />
monitor. The changeover is menu controlled.<br />
HOW IS THE SYSTEM BROUGHT UP TO<br />
TEMPERATURE?<br />
When filling hot, the first thing is to bring<br />
the filler up to temperature. This is done<br />
by circulating hot water through the filling<br />
valves and ring bowl directly after the<br />
sterilization process. When the whole system<br />
has been heated to a specified temperature,<br />
the water is removed. The heated<br />
product is now initially circulated from the<br />
tubular ring bowl likewise through all filling<br />
valves. The filling process does not start<br />
until the product return temperature<br />
matches the required filling temperature.<br />
The process is the same as with pressureless<br />
filling. The product is now no longer<br />
circulated within the filling system. Heated<br />
product is supplied to the filling valves<br />
directly from the tubular ring bowl.<br />
WHAT TEMPERATURES ARE POSSIBLE?<br />
The filling temperature is always determined<br />
by what the product demands with regard<br />
to the necessary pasteurization units and<br />
is the basis for the heat stability of the plastic<br />
bottles used. Filling temperatures of<br />
up to 95 degrees Celsius are always possible.<br />
When defining the temperatures, <strong>KHS</strong><br />
is not only available to give advice but can<br />
also carry out practical tests in advance in<br />
the <strong>KHS</strong> Technical Center. This additionally<br />
shows whether the intended plastic bottles<br />
are suitable for the particular application.<br />
IS MICROBIOLOGICAL SAFETY<br />
ALSO ENSURED DURING FILLING<br />
INTERRUPTIONS?<br />
Shortage of bottles, backup at upstream<br />
machines – there are many reasons for interruptions<br />
in filling. In such cases, the system<br />
again circulates the product through<br />
the filling valves and tubular ring bowl. This<br />
prevents cooling below the required pasteurization<br />
temperature. Hot product is<br />
always ready at the valve seat. Tubular ring<br />
bowl and valves are at the correct temperature<br />
to ensure microbiological safety. Hot<br />
filling can therefore be resumed at any time.<br />
This contributes to the high availability of<br />
the filling system. Circulation of the product<br />
avoids phase separation in the case of<br />
technology+innovation °<br />
products containing pulp or fibers. The quality<br />
of the product entering the plastic bottle<br />
is therefore consistent at all times.<br />
ARE THERE ANY SPREADERS?<br />
As with all versions of the Innofill DRV, the<br />
liquid film in the Innofill DRV-VF/NH is<br />
formed using a swirler. This is decisive for<br />
hygiene. In this way, there are no spray elements<br />
protruding into the bottle. A further<br />
plus point is that using a swirler ensures<br />
high flexibility. Widely differing shapes and<br />
sizes of bottle can be filled by means of a<br />
swirler without any previous changeover<br />
work – within the possible bottle capacities<br />
specified by the system ranging between<br />
0.1 and 3.0 liters.<br />
HOW IS SANITIZING DONE?<br />
With the Innofill DRV generation of fillers,<br />
the CIP sanitizing process has also been<br />
solved in an extremely advantageous way.<br />
So-called CIP plates are either inserted manually<br />
or moved fully automatically over the<br />
mouths of the filling valves. The same principle<br />
of pressing bottles against the filling<br />
valves during pressurized filling is used for<br />
the CIP sanitizing process. In this case,<br />
however, the filling valves are sealed by the<br />
pressure of the rinsing solution – fully automatically<br />
and exactly adapted to the internal<br />
pressure.<br />
50*51
For non-alcoholic beverages: Now integrated hot-fill version for PET<br />
WHAT ADVANTAGES DOES THE TUBU-<br />
LAR RING BOWL OFFER?<br />
The tubular ring bowl of the DRV generation<br />
of fillers is considerably lighter in weight<br />
than the classical angular ring bowl solution.<br />
There are no corners or edges – this<br />
ensures maximum hygiene. And the lightweight<br />
construction requires less drive force.<br />
Furthermore, significantly less energy is<br />
required for heating and cooling.<br />
WHAT OUTPUTS ARE POSSIBLE?<br />
When hot filling, the Innofill DRV-VF/NH<br />
processes up to 60,000 bottles per hour.<br />
When filling fruit beverages, the fruit/pulp<br />
content in the beverage can be up to 8 percent.<br />
The system even processes fibers up<br />
to 5 millimeters long and up to 1.5 millimeters<br />
in diameter.<br />
HOW HIGH ARE INVESTMENT COSTS?<br />
Even if those who are not certain today<br />
whether hot-filling is likely to be a consid-<br />
With the Innofill NV-H, the non-contact filling of plastic bottles by means of a free-flow filling<br />
valve represents the highest microbiological and hygienic safety. Free-flow filling for<br />
the sensitive non-carbonated, alcohol-free beverages intended for hot filling is always carried<br />
out in two stages. Only the liquid seat is energized while the filling process is running<br />
thereby reducing the cost of individual control elements for each filling station.<br />
eration in the future, but who opt for Innofill<br />
DRV filling technology, should invest in the<br />
Innofill DRV-VF/NH version. The additional<br />
costs are reasonable – with the highest possible<br />
flexibility in the future. The hot-fill<br />
option can be easily retrofitted to existing<br />
systems.<br />
WHAT IF ONLY STILL NON-ALCOHOLIC<br />
BEVERAGES ARE TO BE FILLED HOT?<br />
In this case, consideration is given to the<br />
Innofill NV-H, the hot-fill option of the<br />
Innofill NV developed by <strong>KHS</strong>. Special features:<br />
Fruit drinks can have longer fibers<br />
with lengths up to 10 millimeters and diameters<br />
of 2 millimeters. The Innofill NV-H<br />
can also process small pieces of fruit. It is<br />
able to fill up to 60,000 0.1 to 3.0-liter plastic<br />
bottles per hour – and in special cases<br />
up to 5.0 liters. Non-contact filling using<br />
a free-flow filling valve makes the highest<br />
microbiological and hygienic safety possible.<br />
Free-flow hot filling of sensitive noncarbonated<br />
alcohol-free beverages is always<br />
carried out in two stages. Only the liquid<br />
seat is energized while the process is running.<br />
This cuts the cost of having individual<br />
control elements on two solenoid valves<br />
for each filling station. During interruptions<br />
in the filling process, the central return<br />
valve opens and the product recirculates.<br />
The passages are such that the heated external<br />
stainless steel areas keep the product<br />
at the correct temperature even within the<br />
gas lock. And different mouths can also<br />
be processed.<br />
RESULT<br />
With these newly developed hot-fill options,<br />
<strong>KHS</strong> is once again acting as a pioneer in the<br />
market. In particular, the combination filling<br />
systems very clearly show that simple<br />
functionality and a high degree of future<br />
proofing with maximum flexibility of a filling<br />
system do not have to be mutually exclusive.<br />
On the contrary, they complement one<br />
another.<br />
Ludwig Clüsserath, Manager, Process Engineering<br />
Competence Center, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.khs.com<br />
• CONTACT<br />
Ludwig Clüsserath,<br />
Manager, Process Engineering Competence<br />
Center, <strong>KHS</strong> AG, Bad Kreuznach<br />
Telefon: +49/6 71/8 52 – 25 01<br />
E-Mail: ludwig.cluesserath@khs.com
<strong>KHS</strong> sets an innovative milestone with<br />
a comprehensive product line harmonization for<br />
modular packaging technology solutions.<br />
This realignment now also benefits packaging<br />
equipment in the entry and medium capacity range.<br />
As Flexible as the Alphabet<br />
The market is demanding individual solutions, particularly when it<br />
comes to the increasingly important packaging technology. This<br />
is exactly what <strong>KHS</strong> has been offering for some time in the form of<br />
high-performance, modular packaging equipment. Customers from<br />
the beverage, food, or non-food sectors can configure function<br />
modules for shrink packers, tray shrink packers, pad shrink packers,<br />
and wrap-around packers to form optimize systems for the<br />
respective task. After the product line harmonization, <strong>KHS</strong> now<br />
also offers modular solutions for packaging systems with smaller<br />
and medium capacity, so that medium-sized companies, too, can<br />
benefit from maximum flexibility.<br />
ADVANTAGE NO. 1: SOLUTION GROWS WITH REQUIREMENTS<br />
Product line harmonization will make future changeovers even simpler,<br />
faster, and above all more versatile. The technical solution<br />
can simply grow with user requirements, and not just in terms of<br />
packaging type or performance increase. Integrating equipment<br />
such as the leaflet inserters, film perforators, partition inserters,<br />
or tray stackers is just as feasible as converting existing equipment<br />
to new areas of application.<br />
ADVANTAGE NO. 2: UNITS BECOME TRANSPARENT<br />
The function modules are self-contained units that can easily be<br />
removed from or integrated into the overall system. Interfaces can<br />
be clarified quickly. Individual functional units become transparent<br />
for the user, making the respective packaging solution more<br />
comprehensible. The principle: The technology is more manageable<br />
and maintenance is simplified.<br />
ADVANTAGE NO. 3: IDENTICAL SERVO MOTORS<br />
Identical servo motors are used for all functional units. This simplifies<br />
spare-parts stocking, among other benefits. The innovative<br />
servo motors feature integrated servo controllers offering<br />
further improvement in communication compared with previous<br />
Product line harmonization at <strong>KHS</strong>:<br />
Packaging technology for the future<br />
servo motor models. A master controller in the control cabinet controls<br />
these MI servo motors. A single connecting line between the<br />
control cabinet and the first servo motor in respective packer segment<br />
is sufficient for perfect communication. Up to twenty ultracompact<br />
servo drives can be connected in series via a hybrid cable.<br />
Numerous previous cable connections are no longer required, the<br />
control cabinet can be much smaller, and the lack of control units<br />
means that cooling equipment may no longer be required. The<br />
servo motors and the individual functional units are connected via<br />
plug connectors. This simplifies replacement of servo motors and<br />
commissioning of the packaging machine.<br />
ADVANTAGE NO. 4: NEW DESIGN – SIMPLE AND HYGIENIC<br />
The revision of the packaging machine design led to a cubic machine<br />
frame. Together a new protective hood design, this offers machine<br />
operators even better insight into the ongoing packaging process.<br />
Access for the purpose of operation and maintenance has also been<br />
optimized further. Easy to clean assembly support systems were<br />
integrated for hygiene reasons. Together with the newly designed<br />
catch pans for cleaning agent, rinse water, and possible product<br />
leaks located below the function modules, this ensures maximum<br />
hygiene. Any protruding parts such as bolts or bars for fastening<br />
adjustable guides are now hinged or no longer required. Wherever<br />
possible, the new product line uses low-noise cog belts with<br />
simple design and maintenance-free operation.<br />
52*53<br />
Adjustment points with spindle adjustment: A central controller supplies the<br />
new target position for format changeover. The Accu-Drive unit receives the<br />
target position via an infrared interface.
<strong>KHS</strong> packaging technology for the future<br />
ADVANTAGE NO. 5: FULLY C<strong>US</strong>TOMIZABLE<br />
The modular system enables simple mechanical, semi-automatic,<br />
or fully automatic adjustments. This is particularly important for<br />
food processing companies wishing to use the same packaging<br />
machine for a variety of formats, for example. Clamping levers are<br />
used for manual changeovers. Alternatively, operator-controlled<br />
adjustment units based on electronic displays with acknowledgement<br />
function can be used for format changeovers. Manually maintained<br />
hardcopy lists are therefore no longer required, and the error<br />
rate drops to a minimum. A modified cordless screwdriver makes<br />
handling of operator-controlled adjustment units even more convenient.<br />
The cordless screwdriver communicates directly with the<br />
central controller via a field bus system. This ensures maximum<br />
precision, even for fully automatic changeovers. For fully automatic<br />
format changeovers, the adjustment units are equipped<br />
with drives that have to be activated sequentially via graphical<br />
menu-driven operating at the monitor.<br />
ADVANTAGE NO. 6: EVEN MORE VERSATILE PRODUCT<br />
GROUPING OPTIONS<br />
The product grouping function module offers even greater flexibility.<br />
In the past a sectioning unit with two servo drives was used<br />
2<br />
COMPONENT SPECIAL FEATURES ADVANTAGE<br />
Drive<br />
Wiring<br />
Machine frame<br />
Drive transmission<br />
Machine cladding<br />
Guide rails<br />
THE ADVANTAGES OF PRODUCT LINE HARMONIZATION<br />
Product formation grouping<br />
Film cutting station<br />
• Feed system<br />
• Packaging material<br />
• Cutting tool<br />
• Design<br />
• Feed belts<br />
Film wrapping<br />
Shrink tunnel<br />
Identical servo motors in all functional units<br />
Wiring of up to 20 servo motors via a hybrid cable; cable<br />
connections in the control cabinet with contact strips<br />
Cubic design, new assembly support system<br />
Cog belt<br />
New safeguards<br />
Suspension from above<br />
Up to four servo motors, individually<br />
scalable for any task<br />
Variable width, larger width, cog belt<br />
drive<br />
Thinner films can be processed<br />
Drive with servo motor, cog belt drive<br />
Gap dimensions reduced, fewer guides<br />
Antistatic, improved hole pattern<br />
Height-adjustable, electronically controlled curve<br />
Eco shrink tunnel, optional gas heating<br />
that was designed for the largest product formation expected to<br />
be processed with the system. This meant that smaller units had<br />
to be conveyed with substantially higher speed, resulting in suboptimal<br />
utilization of the packaging machine. With the new sectioning<br />
unit up to four servo motors with speeds that are precisely<br />
adapted to the respective type of packaging can be used. Each<br />
servo motor has its own sectioning tool allocated. Outputs of up<br />
to 120 cycles per minute are now also possible for PET bottles.<br />
The data for optimum sectioning are stored in the system for each<br />
individual product formation.<br />
Easy to service, better spare parts management,<br />
faster troubleshooting<br />
Less space required in the control cabinet, simple wiring,<br />
plug connections, error avoidance<br />
Greater clarify, better access, optimized hygiene,<br />
suitable for retrofitting<br />
Less noise and maintenance<br />
Optimum process monitoring, convenient handling,<br />
vertical-lift doors as standard, optional sliding doors<br />
Simplified format changeover, laterally protruding bars<br />
are eliminated<br />
Optimum speed for each product configuration,<br />
higher speeds<br />
Flexible adaptation to the position of different film<br />
widths, greater format range, noise reduction<br />
Increased range of films for processing, cost reduction for<br />
packaging material, longer service life<br />
Maximum cutting precision, low wear<br />
Efficient operation<br />
Increased film feed reliability<br />
Perfect positioning accuracy, high degree of flexibility<br />
Low energy consumption, very exact temperature control,<br />
shorter heating phase
Left Cubic machine frame, integrated control elements, vertical-lift or sliding doors, optimum process<br />
monitoring, hygienic design. Center Automatic guide rail adjustment via direct drive. Right Electronic<br />
displays with acknowledge function guide the operator through the format changeover.<br />
ADVANTAGE NO. 7: VERY THIN FILM IS POSSIBLE<br />
A new film cutting and conveyor system enables processing of thinner<br />
films. Added to this: The new film cutting station is bigger,<br />
offering greater flexibility in terms of film width. A servo-driven<br />
cutter cuts the film with maximum precision and minimum cutter<br />
wear. Within the film cutting station, the gap dimensions at transitions<br />
and the number of guides have been reduced significantly.<br />
The film conveyor system has special coatings and new, conductive<br />
conveying belts. This reduces the risk of the film sticking,<br />
winding, or tearing. In conjunction with an additional antistatic<br />
system, it offers maximum conveying stability, even for very sensitive<br />
film types. The feed rollers are hinged for improved access<br />
during maintenance and to facilitate film threading.<br />
ADVANTAGE NO. 8: SHRINK TUNNEL OPTIONALLY<br />
WITH GAS HEATING<br />
The shrink tunnel can either be operated with conventional electric<br />
heating, or the new <strong>KHS</strong> eco-shrink tunnel with gas heating<br />
can be used. This reduces the running costs by up to 50% and CO 2<br />
emissions by up to 60%. Both shrink tunnel versions feature the<br />
familiar hot air nozzle arrangement in the shrink tunnel cover. It<br />
goes without saying that the innovative format changeover solution<br />
can also be used in the new shrink tunnel. The shrink tunnel<br />
section can be complemented with modular components such as a<br />
cleaning facility, cooling fans, or advanced camera technology for<br />
monitoring the shrink process.<br />
THE RESULT: HARMONIZATION BEARS FRUIT<br />
Overall, the expanded <strong>KHS</strong> range of modular packaging equipment<br />
in conjunction with the new product line offers numerous<br />
benefits over the whole capacity range for the beverage, food,<br />
and non-food industries. The crucial factor is the future proofness<br />
of the technology. The new system is highly versatile. Function<br />
modules can be removed or added; packing output can be<br />
increased or decreased. Modular components can quickly be installed<br />
in the required packaging machine. Not to forget: All function modules<br />
not only contain the latest technical achievements, but are<br />
also based on extensive <strong>KHS</strong> experience with packaging applications.<br />
This is exactly what the market needs.<br />
Norbert Pastoors, Manager,<br />
Packaging Technology Competence Center, <strong>KHS</strong> AG<br />
Werner Oster, Product Support Manager,<br />
Packaging Technology Competence Center, <strong>KHS</strong> AG<br />
Werner Ageling, Product Management Manager,<br />
Packaging Technology Competence Center, <strong>KHS</strong> AG<br />
fi<br />
INFOBOX<br />
• WEBSITE www.khs.com<br />
• CONTACT<br />
Norbert Pastoors, Manager, Packaging Technology<br />
Competence Center, <strong>KHS</strong> AG, Kleve<br />
Tel: +49/28 21/5 03 – 2 21<br />
E-mail: norbert.pastoors@khs.com<br />
Werner Oster, Product Support Manager, Packaging<br />
Technology Competence Center, <strong>KHS</strong> AG, Kleve<br />
Tel: +49/28 21/5 03 – 1 52<br />
E-mail: werner.oster@khs.com<br />
Werner Ageling, Product Management Manager,<br />
Packaging Technology Competence Center, <strong>KHS</strong> AG, Kleve<br />
Tel: +49/28 21/5 03 – 2 37<br />
E-mail: werner.ageling@khs.com<br />
54*55
The bon mot “There are three types of lies:<br />
lies, damned lies and statistics” is attributed<br />
to the politician Benjamin Disraeli<br />
(1804-1881). No one is quite sure about<br />
the origin, but it indicates the significance<br />
of improper use of statistics. If someone<br />
has something to hide, they use a statistical<br />
trick and hope that no one will notice<br />
the hidden numbers. You think you won’t<br />
fall for this? No, you are set straight every<br />
day. No one is safe from misinterpretations.<br />
There are people who deliberately<br />
select lottery numbers that haven’t been<br />
drawn for a while, in the hope that “Surely<br />
they’ll have to appear at last.” Unfortu-<br />
nately, lottery balls have no memory and<br />
no conscience. It is irrelevant how often or<br />
infrequently they have appeared in the past.<br />
They appear based on the laws of statistics,<br />
and with the same probability for each lottery<br />
player. For your information: The probability<br />
is around 1:14 million. Accordingly,<br />
you would have to play over 14 million times<br />
to get six matching numbers. Let’s approach<br />
the basics of statistics in consecutive stages.<br />
STAGE 1: THE MEAN VALUE<br />
The mean value is probably the best-known<br />
statistical parameter. It is also known as<br />
the average and plays a significantly greater<br />
role than is generally assumed. The calcu-<br />
Technical terms in practice:<br />
Don’t be afraid of statistics (Part 1)<br />
MAGIC<br />
NUMBERS<br />
The word “statistics” alone makes some people turn away or tremble with awe. After<br />
all, it has to do with mathematics and mysterious symbols. But then again, statistics<br />
are all around us on a daily basis: We have all heard of the Dow Jones Index and have<br />
seen population statistics. We are therefore much more familiar with numbers than we<br />
think. Let’s try to discover this secret language step by step.<br />
lation is simple, and for small numbers it<br />
doesn’t require a computer. Simply add up<br />
the numbers and divide the result by the<br />
number of individual values.<br />
Example 1: Several people buying<br />
drinks want to find out how many bottles<br />
they buy on average.<br />
Person 1 = 3 bottles<br />
Person 2 = 6 bottles<br />
Person 3 = 20 bottles<br />
Values added: 3+6+20 = 29 bottles.
The total divided by the number of persons:<br />
29/3 = 9.7 bottles<br />
The formula means: Add up all values x,<br />
starting from the first (i=1) until the last<br />
value (n) is reached, and divide the result<br />
by the number (n) of values.<br />
The layman is surprised by the result, and<br />
the expert can pretentiously explain that<br />
the spread in the population is already relatively<br />
large. This gobbledygook means that,<br />
if the individual values are very different,<br />
averaging is not very meaningful. It is similar<br />
to saying, "If I eat two geese and you<br />
eat none, on average, we’ll have eaten one<br />
goose each.”<br />
Nevertheless, the average often has<br />
an almost magical effect and people often<br />
forget that it is merely a guide for the order<br />
of magnitude, rather than a prognosis for<br />
an individual scenario. Therefore, the mean<br />
value is only meaningful for a large number<br />
values or for situations where the individual<br />
numbers are more similar.<br />
How can I nevertheless solve the<br />
dilemma if I want to know the approximate<br />
mean number of bottles in example 1? This<br />
is what the median is for.<br />
STAGE 2: THE MEDIAN<br />
More magic? The median is also referred<br />
to as the middle number or central value<br />
in any given set of numbers or values. The<br />
median for the first example is 6. The situation<br />
would be as simple as that if we always<br />
had to deal with an odd set of numbers.<br />
Unfortunately, we also have even sets of<br />
numbers, and in addition they are usually<br />
unordered. The sets therefore have to be<br />
sorted in ascending order to find the middle<br />
value.<br />
But that’s not all. There are several statistical<br />
options for calculating a mean value,<br />
depending on the problem. It also requires<br />
a certain understanding of the situation,<br />
because there is no infallible means and<br />
no infallible mean value. For the sake of<br />
completeness, it is worth at least mentioning<br />
these other options without further elaborating<br />
on them: They are the harmonic<br />
mean, the geometric mean and the weighted<br />
mean.<br />
STAGE 3: STANDARD DEVIATION AND<br />
VARIANCE<br />
Let’s move on to another big issue that<br />
causes many doubts about statistics: the<br />
standard deviation and the variance. Both<br />
are closely related, as we’ll see shortly.<br />
Example 2: A so-called original list<br />
contains the incomes of 25 families in a city,<br />
let’s call it Rich City.<br />
Income<br />
1,200,000 60,000 45,000<br />
150,000 51,000 42,000<br />
86,000 49,000 38,000<br />
37,000 20,000 14,000<br />
35,000 18,000 13,000<br />
32,000 18,000 11,000<br />
29,000 18,000 10,000<br />
26,000 16,000<br />
24,000 16,000<br />
The arithmetic mean value gives us a result<br />
of 82,320 euros but it totally distorts the<br />
picture, because the single millionaire family<br />
earning more than all others together<br />
dominates the figures. The range isn’t helpful<br />
either in this case: It is the difference<br />
between the lowest and the highest value,<br />
i.e. 1,190,000 euros. But this doesn’t really<br />
help either. Looking at the numbers in the<br />
original list, it is clear that mean earnings<br />
must be in the region of around 30,000<br />
euros. This is where the median comes in,<br />
i.e. the middle value from an ordered list,<br />
in this case 29,000 euros. As you can see,<br />
technology+innovation ° 56*57<br />
it is helpful to reflect on the problem in<br />
order to glean meaningful information about<br />
the population of values. At the same time,<br />
it is clear that the spread of values is important,<br />
but at this stage, we don’t know how<br />
to get a more precise feel for it. Once again,<br />
statistics can help solve this dilemma. It<br />
offers the standard deviation as a measure<br />
of dispersion. Sometimes the term variance<br />
is used, which is directly related to the standard<br />
deviation, i.e. the variance is the square<br />
root of the standard deviation, or in mathematical<br />
terms:<br />
where<br />
var = variance<br />
xi = measured value at point i<br />
_<br />
x = mean value (read as: x bar)<br />
n = number of measured values<br />
s = standard deviation
Technical terms in practice<br />
What exactly is the standard deviation? It<br />
is a measure for the spread of the individual<br />
values. Let’s look at a target as another<br />
example. If a number of shots are fired, the<br />
holes will be scattered around the center.<br />
If they are at the center or close to it, they<br />
came from a marksman. If the shooter was<br />
less skilled, the holes will be further apart.<br />
A simple example can illustrate the calculation<br />
if the standard deviation.<br />
The results after two shooters have<br />
shot at a target are as follows:<br />
Shooter 1 Shooter 2<br />
7 1<br />
8 10<br />
9 13<br />
Mean value 8 8<br />
Anyone can see that one shooter shoots<br />
more precisely than the other. While the<br />
mean value is the same in both cases, the<br />
spread of the results can provide additional<br />
information. Let’s calculate the distance,<br />
i.e. the difference of the results from the<br />
respective mean value, and put the values<br />
in a table:<br />
Shooter 1 Shooter 2<br />
Result Deviation from Result Deviation from<br />
mean value mean value<br />
7-8 -1 1-8 -7<br />
8-8 0 10-8 2<br />
9-8 1 13-8 5<br />
It wouldn’t make sense to simply add up the<br />
negative and positive deviations, but a mathematical<br />
trick called squaring makes them<br />
all positive.<br />
Shooter 1 Shooter 1<br />
Deviation from Square of Deviation from Square of<br />
mean value the deviation mean value the deviation<br />
-1 1 -7 49<br />
0 0 2 4<br />
1 1 5 25<br />
Total 2 Total 78<br />
The difference in the sum of squares between<br />
78 and 2 is very significant. The greater the<br />
distance from the mean value and more individual<br />
results are added, the greater the<br />
sums. We therefore have to take into account<br />
the number of individual results by dividing<br />
the calculated sum by the number of<br />
individual values. This is known as the variance,<br />
and the square root of it is the famous<br />
standard deviation.<br />
Shooter 1 Shooter 2<br />
Variance 2 / 3 = 0.67 78 / 3 = 26<br />
Standard<br />
deviation<br />
It is immediately obvious that the shots from<br />
the first shooter have a lower scattering<br />
range than those from the second shooter,<br />
and that he is therefore the better marksman.<br />
The variance is a common theme in statistics,<br />
right up to the distant heights of variance<br />
analysis. The mathematical/statistical<br />
significance of the variance is tremendous:<br />
It eliminates negative values and at<br />
the same time highlights larger deviations.<br />
If one arranges the shots along a line, the<br />
spread becomes clearly evident.<br />
Shooter 1 = yellow fields<br />
Shooter 2 = blue fields<br />
Mean value = red<br />
1 2 3 4 5 6 7 8 9 10 11 12 13<br />
-7<br />
+1<br />
0 +2<br />
In one case the spread is less than 1, in<br />
the other it is more than 5. While two of<br />
the shots from the second marksman were<br />
closer to the center, the scatter between<br />
the individual shots was high. An additional<br />
-1<br />
+5<br />
fi<br />
INFOBOX<br />
• WEBSITE www.khs.com<br />
• CONTACT<br />
Priv.-Doz. Dr.-Ing. Hartmut Evers,<br />
Laboratory and Technology Center<br />
Manager, <strong>KHS</strong> AG, Bad Kreuznach<br />
Tel: +49/6 71/8 52 – 2252<br />
E-mail: hartmut.evers@khs.com<br />
statistical function can be used to prove<br />
this. The coefficient of variation (CV) indicates<br />
the relationship between the standard<br />
deviation and the mean value.<br />
The mathematical expression for the<br />
variation coefficient is<br />
We calculate as follows:<br />
Shooter 1<br />
Shooter 2<br />
A rule of thumb says that a CV of more than<br />
30% indicates strong inhomogeneity of the<br />
individual values. In our case, this means:<br />
Shooter 2 is not concentrated enough, and<br />
the shots scatter too far. While we had<br />
already suspected this, we now have statistical<br />
proof.<br />
Priv.-Doz. Dr.-Ing. Hartmut Evers, Laboratory and<br />
Technology Center Manager, <strong>KHS</strong> AG, Bad Kreuznach
MUMBAI, INDIA<br />
ELEPHANT PARADE<br />
In February 2009, the Elephanta Festival will take place<br />
on Elephanta Island in the Indian state of Maharashtra,<br />
only ten kilometers from the port of Mumbai. Traditional<br />
music, dance, regional delicacies, and a varied<br />
cultural program presented by renowned national<br />
artists or local fishermen make the festival an unforgettable<br />
experience. The illuminated Maheshmurti cave,<br />
the largest of the 1000 year-old caves on the island,<br />
which are home to the god Shiva, is a unique spectacle.<br />
Take the ferry from the Gateway of India at the port<br />
of Mumbai. Information and dates: www.maharashtratourism.gov.in<br />
ZURICH, SWITZERLAND<br />
WHISKY & CIGAR FESTIVAL<br />
The legendary Whiskyship & Cigar Festival will start on Swiss<br />
Lake Zurich for the tenth time at the end of November (27<br />
to 30). With round 850 different malt whiskies and 300<br />
select cigars from the finest portfolios available it is the<br />
biggest event of its kind. Nine ships, fifty exhibitors, and<br />
dozens of organizers will be participating in the event. Info:<br />
www.whiskyship.ch<br />
DON’T MISS THE OPPORTUNITY<br />
STOPOVER<br />
stopover ° Don’t miss the opportunity<br />
<strong>KHS</strong> customers are active on all continents.<br />
Their work takes them to many countries around the<br />
world to call on customers, to attend meetings and<br />
trade fairs. Such trips sometimes offer a welcome<br />
opportunity for interesting excursions. Here are<br />
a few tips for different stopovers.<br />
LAS VEGAS, U.S.A.<br />
CHER’S COMEBACK AT CAESARS<br />
Almost three years after her farewell tour, the American pop icon Cher returned<br />
to the place where her career started in the mid-sixties: The singer will be<br />
appearing four times a week at Ceasars Palace in Las Vegas until her probably<br />
last show in 2011. Cher has sold more than 100 million sound carriers and is<br />
the only artist worldwide to have had Number One hits or Top Ten hits in each<br />
of four decades. Tickets: www.ticketmaster.com or www.bestofvegas.com<br />
SYDNEY, A<strong>US</strong>TRALIA<br />
HIGHLIGHT DOWN UNDER<br />
The Sydney Festival, which first began in 1977 as an annual event<br />
held at the beginning of the year, offers superlative cultural entertainment,<br />
and is the highlight of the Australian cultural calendar. In around<br />
80 individual events over a three-week period (ranging from pop concerts<br />
to classical evenings in the world-famous opera house) more than<br />
500 artists will perform to an audience of several million people. Further<br />
information about the 2009 Festival (10 to 31 January) will be<br />
available over the coming weeks at www.sydneyfestival.org.au.<br />
MUNICH, GERMANY<br />
BURNT PUNCH XXL<br />
From mid-December 20<strong>08</strong> to early January 2009, the world’s biggest<br />
burnt punch will be simmering at Munich’s historic Isartor. The preparation<br />
alone is a spectacle in itself: After dark, giant sugar loaves are<br />
flambéed over a specially made, two and a half meter high, 9000liter<br />
capacity copper kettle. The legendary classic film “Die Feuerzangenbowle”<br />
starring Heinz Rühmann complements the scenario.<br />
Insights: www.die-kessel-gbr.de<br />
58*59
Adresses<br />
<strong>KHS</strong> AG<br />
Juchostraße 20<br />
D-44143 Dortmund, Germany<br />
Tel +49/2 31/5 69-0<br />
Fax +49/2 31/5 69-15 41<br />
E-Mail: info@khs.com<br />
Planiger Straße 139-147<br />
D-55543 Bad Kreuznach, Germany<br />
Tel +49/6 71/8 52-0<br />
Fax +49/6 71/8 52-2411<br />
Enzingerstraße 139<br />
D-67551 Worms, Germany<br />
Tel +49/62 47/97-0<br />
Fax +49/62 47/97-32 15<br />
Ruwoldtweg 14<br />
D-22309 Hamburg, Germany<br />
Tel +49/40/6 37 03-3 71 00<br />
Fax +49/40/6 37 03-3 71 50<br />
Boschstraße 1-3<br />
D-47533 Kleve, Germany<br />
Tel +49/28 21/5 03-0<br />
Fax +49/28 21/2 61 10<br />
Am Kirchfeld 3<br />
D-34454 Bad Arolsen, Germany<br />
Tel +49/56 91/89 09-0<br />
Fax +49/56 91/89 09-15<br />
Kapellenstraße 47-49<br />
D-65830 Kriftel, Germany<br />
Tel +49/61 92/4 91-0<br />
Fax +49/61 92/4 91-144<br />
Industriegebiet Scheid 16<br />
D-56651 Niederzissen, Germany<br />
Tel +49/26 36/9746-0<br />
Fax +49/26 36/9746-45<br />
<strong>KHS</strong> CORPOPLAST GMBH & CO. KG<br />
Meiendorfer Straße 203<br />
D-22145 Hamburg<br />
Tel +49/40/67 907-0<br />
Fax +49/40/67 907-100<br />
<strong>KHS</strong> UK LTD.<br />
Unit 6 Monkspath Business Park,<br />
Highlands Road<br />
Shirley Solihull, Great Britain<br />
West Midlands B 90 4NY<br />
Tel +44/121/713-6900<br />
Fax +44/121/713-6935<br />
E-mail: info@khs.com<br />
<strong>KHS</strong> <strong>US</strong>A, INC.<br />
880 Bahcall Court<br />
Waukesha, WI 53186, U.S.A.<br />
Tel +1/262/797-7200<br />
Fax +1/262/797-0<strong>02</strong>5<br />
E-mail: mike.brancato@khs.com<br />
5501 N. Washington Blvd.<br />
Sarasota, FL 34243, U.S.A.<br />
Tel +1/941/359-4000<br />
Fax +1/941/359-4043<br />
E-mail: randy.uebler@khs.com<br />
<strong>KHS</strong> PACIFIC PTY. LTD.<br />
P.O. Box 378<br />
1-3 Freight Road<br />
Tullamarine, Vic. 3043, Australia<br />
Tel +61/393/35-1211<br />
Fax +61/393/35-1331<br />
E-mail: info@khspacific.com.au<br />
<strong>KHS</strong> ASIA PTE. LTD.<br />
25 International Business Park<br />
# 3-15/19 German Centre<br />
Singapore 609916<br />
Tel +65 6560-9313<br />
Fax +65 6560-9910<br />
E-mail: info@khsasia.com<br />
<strong>KHS</strong> MACHINERY PVT. LTD.<br />
15, Madhuban, Nr. Madalpur Underbridge<br />
Ellisbridge, Ahmedabad - 380 006, India<br />
Tel +91/79/2644-0331<br />
Fax +91/79/2644-5146<br />
E-mail: khs@khsindia.com<br />
<strong>KHS</strong> worldwide: You will find further addresses and contacts at<br />
www.khs.com<br />
Masthead<br />
PUBLISHER<br />
<strong>KHS</strong> AG, Dortmund<br />
EDITORS<br />
Friederike Arndt, Maternus Gemmel, Manfred Rückstein,<br />
jj-media, Cologne<br />
GRAPHICS<br />
Konzeption+Design, Trawny / Quass von Deyen, Cologne<br />
Layout: Yvonne Voss<br />
CONTRIBUTIONS<br />
Werner Ageling, Wolfgang Augel, Jan-Wilhelm Brückel,<br />
Ludwig Clüsserath, Matthias Damm, Priv.-Doz. Dr.-Ing.<br />
Hartmut Evers, Frank Fretwurst, Rainer Hilgert, H. W. Kim,<br />
Erhard Magin, Thomas Matheyka, Colby McLean, Werner<br />
Oster, Norbert Pastoors, Hubert Schiffer, Oliver Schneider,<br />
Frank Schneidermann, Walter Senft, Hideo Suzuki,<br />
Günter Unkrig<br />
TRANSLATION<br />
Fachübersetzungen CP MacKusick<br />
PHOTOS / ILL<strong>US</strong>TRATIONS<br />
Friederike Arndt, Allgäuer Alpenmilch <strong>GmbH</strong>, Timo<br />
Beylemans, Asahi Brewery, Bundesvereinigung Logistik<br />
(BVL), GOLDBECK West <strong>GmbH</strong>, Burkhard Hellwig, Elde<br />
Konserven, Unilever, shutterstock (Kasia, Artifan)<br />
<strong>KHS</strong> journal offers young students and graduates of the<br />
University of Applied Sciences in Dortmund and Münster<br />
the opportunity to put their photography talents into<br />
practice.<br />
This information is non-binding. Only the technical<br />
specifications of our quotes are determinative with<br />
regard to design and scope of delivery.<br />
Subject to design modifications.<br />
30 1992-01-988/2 09<strong>08</strong> GW