KHS Competence 01.2013, english

01.2013
Innovation
High-performance palletizing:
the top performers
» 28
Systems for sectors
Bottling pieces of fruit:
a team tackles big chunks
» 54 Systems for sectors
» 58
Khmer Brewery, Cambodia:
striding to the top
Pole
Position
PET line expertise

Editorial
Prof. E. h. Dr.-Ing. Johann Grabenweger*
CSO, KHS GmbH
* At Brau Beviale 2012 – just before
reaching the pole position (see page 86)
“With KHS technology
our customers hold
pole position worldwide.”

competence 01.2013 02/03
Dear Readers:
KHS can look back on a very successful 2012. This positive development is not only mirrored in
the substantial increase in incoming orders; we consider the growing trust of our customers in
KHS lines and machines to be just as important. More and more in-house international companies
in the beverage industry have now become our regular clients.
Our new Fit4Future campaign launched in 2011, which focuses on gaining greater proximity
to our customers and making us more competitive, has thus borne fruit. We feel that our
customers ’love’ KHS. This appreciation creates a sense of pride among our employees and is a
challenge to us all to become even better and consistently boost the added value we can offer
our customers. We’re therefore working hard to bring our service up to an even higher level.
It’s our aim to provide excellence of service in the very near future; the first steps have already
been taken. In 2012 we considerably increased our service team. Shortening throughput times
is another objective we’re conscientiously working towards. Building up and cultivating longterm
partnerships with our clients is something we take very seriously.
“2013 will also unleash a bevy of innovations.”
As a technological leader in the field KHS has also created several milestones over the past year,
enabling our customers to take pole position. This is illustrated among other things by the great
demand for our ground-breaking labeling machines, in whose development we’ve invested a
lot of time and expertise. The launch of the next generation of fillers has been received just as
positively by our clients. You can read more about the innovations we’ve introduced over the
past few months and study the first user reports in this issue of KHS competence.
In 2013, too, we wish to present our customers with a bevy of efficient new machines and
lines and provide a range of services specifically tailored to the individual needs of beverage
producers. I’d thus like to seize this opportunity to invite you to drinktec 2013, to be held from
16–20 September in Munich, Germany, where KHS will not only have many new features and
improvements on display but also a range of pioneering technology. I am looking forward to
welcoming you to our booth and surprising you with our new developments.
We aim to be your dependable partner in all situations. You can rely on KHS.
I wish you an exciting read!
Best regards,
Prof. E. h. Dr.-Ing. Johann Grabenweger

Contents
06
The trend interview
06
It’s showtime!
Which trends will drinktec 2013 be setting?
Interview with project manager Petra Westphal.
Working together
for top technology
Innovation Page 12–35
Together with our customers and their colleagues in
Sales and Service, the people in the development departments
at KHS pool their knowledge of the market and
their decades of experience with one prime aim: how
can machines and processes be improved even further to
give KHS customers added value – if not a direct competitive
advantage? Read on and learn about our optimized,
cost-efficient technologies for even more flexibility,
improved hygiene, and greater sustainability.
Innovation
12
Working together for top technology
Topic overview.
14
Systematic labeling
Innoket Neo: labeling technology with
an innovative modular system.
20
Simply cool
Innofill ESL: new series perfects the bottling
of still, non-alcoholic beverages.
24
The big mini system
The mini hygiene housing: highly efficient
bottling of water in PET.

competence 01.2013 04/05
28 54 92
28
The top performers
What’s behind KHS high-performance
palletizing technology. State of the art.
34
Airback Plus
Improved technology for stretch blow
molders saves up to 40% of compressed air.
Market report
36
Coca-Cola TNTL / Marston’s /
Bralima / AQS / Kaiserdom / Dubai
Refreshment / Birra Castello / SIBCO /
CCN / Oskar Blues / SABMiller KP /
Pepsi Domodedovo / Distell
KHS customer projects around the globe.
Service
42
The wind of change
The top ten KHS conversions and upgrades.
Giving customers a competitive advantage.
Systems for sectors
48
A big hit with the public
A policy of providing nothing but quality
is behind the success of Lao Brewery –
as is customized technology from KHS.
54
A team tackles big chunks
Hotfill PET line dedicated to chunky fruit
beverages at Kofola.
58
Striding to the top
Khmer Brewery in Cambodia took up production
just one year ago and is already on
the way to becoming a market leader.
64
The keg king
Siberian brewery Bochkari is growing,
producing its beer with the highest performance
keg system in Russia – from KHS.
70
It had to be a CombiKeg
The seventeenth Innokeg Till CombiKeg
supplied by KHS has gone to the
fast-growing Brauerei Egger in Austria.
Specials
74
The future in focus
Sustainability now part of daily business.
80
Spotlight on values
Interview with Anke Fischer, head of Finance,
Human Resources, and IT at KHS.
In-house news
84
News from KHS
Ethical audits / KHS participates in Blue
Competence / Capital Markets Day / Three
trade show reports / The joint rebas project /
KHS supports education in Vietnam / New
assembly shop at KHS Corpoplast / Award
for the KHS InnoPET Blomax Series IV.
90
“That’s my job”
One man and his labeling machine.
92
Click by click
Interactive plant engineering.
93
KHS competence
Publisher’s information and plant addresses.

Interview

competence 01.2013 06/07
It’s showtime!
drinktec 2013 – which trends will the world’s leading trade show for
the beverage and liquid food industry be setting? / Ms. drinktec,
project manager Petra Westphal, gives us a preview – and more – in the
following interview, exclusive to KHS competence.
KHS competence: The name of drinktec has been extended
for 2013. The World’s Leading Trade Fair for the Beverage
and Liquid Food Industry is now The World’s Leading
Trade Fair for the Beverage and Liquid Food Industry
– Processing + Filling + Packaging + Marketing. What’s
the main reason for this?
Petra Westphal: With this new title we’d like to emphasize
that drinktec is much more than just a forum for technology.
Specifically listing individual areas of activity stresses
that the show will not just focus on raw materials and the
filling process, for example, but that packaging and marketing
also play an important role here. In short, everything
that’s important to the beverage and liquid food sector
worldwide will be covered by drinktec.
Petra Westphal, drinktec project manager,
in empty Hall B4. This is
where visitors to drinktec will meet
at the KHS show booth
from September 16 to 20.
How do exhibitors and visitors see the consistent expansion
of the drinktec spectrum?
We already began steering the show in this direction at
the last drinktec in 2009. Since then, a lot has also happened
in the way exhibitors and visitors think. We’re seeing
a much greater interest from the packaging industry,
for instance. We understand drinktec to be an exhibition
that has an innovative and advisory function and shows
initiative, and that acts as a link in all respects. We bring
people, markets, and industries together. This is where
technologists swap views with marketing experts, where
the various markets converge, where the beverage processing
and liquid food industry talk to the supplier industry,
and so on and so forth. In the space of just five days
drinktec thus promotes international exchange on a level
that is second to none.

Interview
“In the space of just five days
drinktec promotes international
exchange on a level that is
second to none.”
The trend interview
In its previous few issues KHS competence ran a series of articles entitled The
trend interview that intend to give readers added value for practical use.
These talks with select experts are designed to provide an insight into future
developments on our global markets, and in the beverage, food, and nonfood
industries in particular. The first interviews held by KHS competence
were …
… with Professor Peter Wippermann, one of the guiding lights in trendrelated
market research, on the general tendencies in the beverage and food
industries;
… with Fred Piercy, business director for wines and spirits at the largest
global packaging company listed on the stock exchange, Amcor Rigid
Plastics, on the trend for wine in PET bottles;
… and with Thomas Haensch, vice-president of Sales, Marketing & Innovation
at Ball Packaging Europe, on the future of the can.
Exhibitor response to drinktec 2009 was extremely
positive. Is this why you’re reckoning on even more
exhibitors taking part in 2013?
We are indeed expecting an increase in the number of
exhibitors, with even more coming from outside Germany
this year, totaling around 1,500 exhibitors from over
70 countries. We undoubtedly owe this plus in part to
the outstanding performance of the show in 2009. Despite
the economic crisis at that time, drinktec managed
to crank up the investment machine and get the ball rolling
again.
In which area will there be a particular increase
in the number of exhibitors?
As always the largest exhibition area at drinktec will be devoted
to what’s known as product-specific process technology
that deals with the production and processing of
beverages and liquid foods. Seven of the twelve halls and
thus 80,000 m 2 are reserved for this section of the show.
We’re seeing a moderate growth here although Hall B3,
which is in the product-specific process technology section
and will be featuring everything to do with PET, has
thus far shown an above-average increase in the number
of exhibitors. Exhibitor demand for space in global product
processing technology is also on the up. The raw materials,
packaging, and marketing sections continue to be
in very high demand for 2013.
At drinktec 2009 energy efficiency, saving water, and
sustainability were the center of both exhibitor and visitor
attention. Where do you see the priorities for 2013?

competence 01.2013 08/09
Minimizing the use of resources through intelligent and
innovative processes will also be of great significance in
2013. We’re also seeing line flexibility, hygienic design,
and quality assurance becoming major points. And whatever
the topic, it often all boils down to economy in the
end. This watchword will act as a bracket for all of the innovations
on display at drinktec 2013.
How many visitors do you think will attend?
We’re reckoning on about 60,000 visitors to drinktec from
over 170 countries of the world, with approximately 60%
of our trade visitors arriving from outside Germany. We’re
also seeing interest in the show continuing to grow in
Asia, Central and South America, and Africa.
drinktec acts as co-organizer of the two beverage trade
shows drink technology India and International Pack
Tech India and of China Brew China Beverage. Could this
result in a cannibalization of visitor numbers in Munich?
Just the opposite. Through our additional presence in India
and China we’re enjoying excellent communication
on drinktec. At the same time we’re awakening a distinct
curiosity among visitors to these exhibitions only geared
towards local markets about the world’s leading trade fair
for the beverage and liquid food industry. They understand
very well that drinktec features the full spectrum,
providing a very holistic view of things. Incidentally, in
the future we don’t intend to merely function as coorganizers
on the Asian markets.
From which areas of the beverage industry are you
expecting an increased number of visitors?
The probable visitor structure can already be derived from
the range of exhibitors for the individual sectors. Around
74% of all exhibitors in 2013 will be offering systems for
the brewing industry, approximately 67% for the nonalcoholic
beverage sector, about 55% for the wine, sparkling
wine, and spirits segment, and another 50% for
the milk and liquid food industry. Compared to the last
drinktec the focus has again clearly shifted towards nonalcoholic
beverages and the milk and liquid food sector.
About 10% more exhibitors will be addressing this target
group, among others. All told, in 2013 we estimate that
40% of our trade visitors will be from the brewing industry,
at least 30% – and probably more – from the milk and liquid
food industry, and the remaining 30% from the other
segments mentioned. We believe that the number of visitors
from the non-alcoholic beverage and liquid food industries
will continue to rapidly grow in the future, too.
Will most of the trade visitors to the show be top
management and decision-makers?
The trend is pointing this way, yes. However, we’d prefer
this not to be the case entirely. We tell companies to
not just send executives to the show but also the people
who work on the machines. It’s extremely important for
these employees to know which way the wind’s blowing.
If they’re given another access to developments on
“We tell companies to not just
send executives to the show
but also the people who work
on the machines.”

Interview
the world markets, they could also begin to see internal
work processes from a different angle, optimizing workflows
and making savings in the interests of the company,
for example. This in turn increases the company’s
competitiveness.
How long do visitors stay at the show? Do you think it’s
still necessary to stay for the full duration?
drinktec lasts a full five days. For exhibitors this length of
time is absolutely essential considering the great amount
of effort they put into the show – not least because one of
drinktec’s trademarks is that complete lines, systems, and
machines are shown in their entirety. With our huge variety
of exhibits I can only urge visitors to absorb as much information
for as long as they can. This is what we think: we
give the world a trade show every four years that takes exactly
these four years to prepare. For this we ask the world
to devote a mere five days of their time once every four
years. Five days – and this is the crux – which help them
to stay competitive in the future as well. Five days during
which the top technology of tomorrow is presented and
ideas for the future evolve which travel right round the
world from one single venue.
Which specific campaigns have the trade show
organizers run to attract visitors from all over the world
to drinktec?
Last year we started an international roadshow with the
VDMA – the German Engineering Federation – during
which we informed opinion formers as to the many benefits
of drinktec. We count various associations and the
press among our propagators as well as potential exhibitors
and visitors from the individual regions. As drinktec
we’re also represented at the industry’s chief events worldwide.
What’s new for this year’s drinktec is that we’re now
also on the social networks. drinktec fans have been discussing
the show for over three years now on Facebook
and Twitter. We think it’s very important to use these
media now to access the target group of tomorrow in
good time.
Many visitors associate an extensive and ambitious
program of events with drinktec. How does 2013 look?
As far as this program is concerned, we’ve deliberately
made several reductions compared to 2009 so that
visitors have enough time to visit the show booths. The
feedback from the industry on this has been extremely

competence 01.2013 10/11
Spotlight:
Munich International
Trade Fairs
→→
Organizer of around 40 trade shows for
capital goods, consumer goods, and new
technologies
→→
One of the five leading trade show
organizers worldwide
drinktec 2013
Munich International
Trade Fairs
Sep. 16–20, 2013
www.drinktec.de
→→
In addition to trade shows in Munich,
Germany, the company also runs
exhibitions in Asia, Russia, the Middle East,
South America, and South Africa
positive. Munich International Trade Fairs has organized
just one forum for this year where the quality of the talks
has been allotted greater importance. The forum is in Hall
A2 and thus freely accessible and fully integrated into
the happenings at the show. Among other things, we’re
especially proud that the Beverage Forum staged by
Beverage World trade magazine will take place on the
Sunday before drinktec 2013 in cooperation with the
trade show to celebrate its twentieth anniversary. This is
where the who’s who of the beverage industry will meet.
The Third Beer Sommelier World Championship will also
take place during drinktec and the European Beer Star and
Beverage Innovation Award will also be presented. There’s
also a PET breakfast meeting where people can talk PET
every morning between 8.30 and 10 am. An Innovation
Flow Lounge is planned for the showground entrance
which is to give marketing and technology experts place
to exchange their views. I think that all of these events
definitely give visitors plenty of added value without overtaxing
them.
Imagine that drinktec 2013 has just ended. What conclusions
would you draw?
If that were so, I’d like to be able to say that the atmosphere
at the show was very good and that as a commercial
platform drinktec had again paved the way to new markets
and new fields of business – because the beverage
producer had spoken to the machine manufacturer; because
the marketing expert had traded information with
the engineer; because the master brewer had chatted to
the CEO of one of the exhibiting companies. And because
this is where the future is made.
Ms. Westphal, thank you very much for talking to us.
The interviewer was Friederike Arndt.

Innovation
Innovation Page 12–35
Working together
on top technology
Together with our customers and their colleagues in Sales and Service,
the people in the development departments at KHS pool their knowledge
of the market and their decades of experience with one prime aim:
how can machines and processes be improved even further to give
KHS customers added value – if not a direct competitive advantage?

competence 01.2013 12/13
14 Innoket Neo: systematic labeling ...
… Various labeling techniques and combinations
… Maximum flexibility and individuality
… Reliability and ease of operation
20 Innofill ESL: simply cool ...
… New machine series for still, non-alcoholic beverages
… Closes the gap on extended shelf life products
… Product safety, flexibility, and resource savings
24 Hygiene housing: the big mini system …
… Bottles water in PET under ultraclean conditions
… Enclosed, highly efficient mini housing
… Saves space, time, and cuts costs
28 KHS high-performance palletizers: the top performers …
… High-performance palletizing technology is state of the art
… Up to 600 layers per hour, with an optional 750 layers per hour max
… Less space, fewer parts, and less maintenance effort required
34 Airback Plus : the cost cutter …
… Improved technology for stretch blow molders
… 40% less compressed air used
… More sustainable – at a considerably lower cost
In the Innovation box you will find a QR code (left) pertaining to each article.
You can use your smartphone to send an email to the person who can provide
more information. Simply download an application (app) which allows you to scan
in the code with the smartphone camera. Some free apps are listed below:
iPhone → AppStore → “RL Classic”
Android → Market → “Barcode Scanner”
Blackberry → App World → “BeeTagg”

Innovation
1
In brief
This is what new, modular Innoket Neo platform
labeling technology from KHS offers you:
2
3
+ Various labeling techniques
+ All possible combinations
+ Compact, space-saving design
+ Ease of operation
+ Gentle container handling
+ Time savings
+ Various installation options: inline or parallel conveying
+ Processing of all shapes and types of container
(cans, glass or plastic bottles,
cylindrical or contour containers)
+ Output of 10,000 to 72,000 containers per hour
+ For containers ranging from 0.1 to 3 liters in size.
4

competence 01.2013 14/15
Innoket Neo
Systematic labeling
Labeling technology based on an innovative modular system. KHS once again
demonstrates its consistent orientation towards the market / Customers
want maximum flexibility and individuality with top quality, reliability and ease
of operation, and a variety of labeling techniques and combinations.
The Innoket Neo is here!
With the range of products continuously on the rise
and ever more diverse forms of packaging, the demands
made by the beverage, food, and non-food industries
on their labeling technology are steadily increasing.
Systems are required
→→
that take into full account the very individual requirements
of each and every customer,
→→
that provide outstanding labeling quality and ease
of operation, and
→→
are not only as compact and space-saving as
possible,
→→
but are also quickly delivered and installed on site.
We’ve got the message. With the new, modular Innoket
Neo labeling machine KHS is meeting the ever increasing
demands of the industry – while naturally looking ahead.
The new platform development with servo drive technology
utilizes all the proven labeling techniques – cold glue,
self-adhesive, hot melt, and roll-fed – and is configured to
match specific customer requirements.
1. Cold glue labeling
2. Self-adhesive labeling
3. Hot melt labeling
4. Roll-fed labeling
The advantage of identical parts:
fast assembly, fast delivery.
The greatest advantage of the new modular system is
that these various processes can be combined with one
another within the machine. Incidentally, the Innoket Neo
is also convincing with its efficient, extremely well engineered
processes, regardless of which type you choose.
And this goes way beyond the actual labeling process. The
following outlines the chief features and innovations of
the Innoket Neo.
No more table setup
The classic table structure has been replaced by a base machine
with a combined carousel and front table. There are
a total of six pitch circle and two front table versions in the
program with star wheel diameters of 472 and 708 mm.
The largest pitch circle is 2,360 mm.
Faster installation
Another major benefit of the Innoket Neo is that it is
quick to install and commission on site. Using prefabricated
modules KHS is able to quickly meet individual customer
specifications. KHS first installs and tests the ordered

Innovation
Also on board: the award-winning ClearLine Human Machine Interface.

competence 01.2013 16/17
Another plus: optimized
warehousing and fast order
processing.
labeling technology at its own factory, thus ensuring that
the required processes can rapidly go into operation without
any hitches when the machine is delivered.
Greater transparency
A glass housing allows operators to observe the current labeling
process at all times. Hinged doors at the front table
and sliding doors at the stations also provide easy access.
Gentler conveying
A servo drive controls the feed screw at the infeed, stopping
the containers if needed and then restarting the flow.
Omission of the stop star previously used makes the machine
more compact and more efficient, with conveying
of sensitive containers in particular much gentler. There
is also no need to change format parts here when switching
container types.
Faster format part changing
The infeed and discharge stars are lightweight and easy to
carry, allowing format parts to be changed without tools
within 10 to 15 minutes. All star wheels are locked in place
by a locking handle with a quick-action fastener and can
be removed on one 90° turn.
Easier cleaning
A much smaller front table with a stainless steel cover now
replaces the former wide table construction. The newly
designed panels cover the gear wheels but no longer extend
laterally beyond the labeling carousel. This makes the
machinery easy to access and simpler and faster to clean
as the surface is much smaller and the floor area easier
to reach.
Optional height adjustment
With the exception of the self-adhesive labeling stations
with integrated height adjustment all stations on the
Innoket Neo are mounted on a standardized base on the
carousel. Height adjustment is also available for this base.
The key advantage: the labeling units can be moved up
and down within a defined range at the press of a button
on the operator console. This does away with the need for
format changeovers when labels of the same size are applied
at different heights on different bottles types. This in
turn saves on format parts and boosts machine efficiency.
Combinations possible
The Innoket Neo can either be configured for one specific
labeling technique or for a number of different combinations.
Should there be a need for changing labeling techniques
at a later date, investment in the modular Innoket
SE from KHS is recommended. This machine enables labeling
stations to be changed at any time.

Innovation
Base Machine: combined carousel and front table.

competence 01.2013 18/19
Variable container plate control
The customer has a choice of three options:
1. V-ribbed belt control is ideal when applying roll-fed or
hot melt sheet-fed labels to round containers.
2. Mechanically controlled cam rotation is suitable for
the cold glue labeling of round containers with no special
requirements (such as alignment with an emblem).
3. Maximum flexibility is provided by the electronic
VarioDrive bottle turret control system for all labeling
techniques and types of container with up to 64 different
programs and the BOS camera system as an option
for particularly tricky labeling jobs.
Optional: empty container labeling
Labels are usually applied to full containers. The Innoket
Neo is also able to process empties. However, plastic bottles
in particular must be stable enough to do so. This is
why sterile air is injected into the bottle – once it has been
centered on the labeling carousel – through a valve located
inside the centering bell. This sterile air is introduced
through the center shaft. The usual air inflow through
control disks is now a thing of the past, the advantage
here being that wear is no longer an issue.
Optional: label position inspection
by camera
If required, as an option the presence and position of labels
can be inspected by a camera system. Inkjet or laser
coding can be applied either at the discharge or in the carousel.
It is also possible to mount a sleever downstream of
the labeling process to apply tamper-evident seals.
To sum up, with the Innoket Neo KHS has systematically
developed a full package of extra benefits for the
market. The Innoket Neo platform expediently meets the
practical requirements of the industry, not only giving it
high-quality label application for all kinds of container but
also eye-catching presentation of their products at the
point of sale. The Innoket Neo: what customers want!
→ Contact
Lutz Körtge
KHS GmbH, Dortmund, Germany
Michael Zwilling
KHS GmbH, Dortmund, Germany
Phone: +49 231 569 10091
Email: lutz.koertge@khs.com
Phone: +49 231 569 1578
Email: michael.zwilling@khs.com
The advantage of the modular
system is that it is quickly installed
and commissioned.
Integrated height
adjustment
Practical example 1:
The wine trade often
applies labels of the same
size to different types
of wine bottle. The only
variation here is invariably
in the application height
of the label.
Practical example 2:
In the brewing industry,
identical back labels are
often used on half-liter
and third-of-a-liter bottles
at different heights.

Innovation
Top-class
hygienic design.

competence 01.2013 20/21
Small sanitary rooms
also for ESL applications.
SIMPLY
Cool
New Innofill ESL series perfects the bottling of still, non-alcoholic beverages
for the cold chain / This innovation closes the gap in filling technology for
Extended Shelf Life products, convincing customers with its maximum product
safety, great flexibility, ease of operation, and noticeable resource savings.
Consumer demands are escalating the world over. They
understandably want their milk and mixed milk beverages,
fruit juices, or the ever more popular yogurt drink
to be fresh – and to have the maximum possible shelf life
stamped on the bottle. At the same time public sensitivity
towards wholesome food is increasing steadily, with shoppers
increasingly avoiding products that contain additives
such as preservatives. All of these challenges can be met
with the right technology.
KHS’ recently developed, extremely compact Innofill
ESL, for instance, satisfies even the most discerning consumer
demands. ESL stands for Extended Shelf Life and
designates products in supermarket refrigerators that
keep as long as possible. With KHS ESL technology all
kinds of still, non-alcoholic beverages can be bottled that
are sold through the cold chain, i.e. the previously mentioned
milk-based drinks and fruit juices, coffees, teas, and
products containing pulp and/or chunks. Similar flexibility
is demonstrated in the range of materials used for the
plastic bottles, such as PET, HDPE, PP, and PE. Square, oval,
and rectangular containers can all be filled as long as their
maximum dimensions have been considered and the neck
rings to be processed are identical (see In brief on page 23).
A win/win situation on all counts
The benefits of this new development are of course evident
in the filled product. Here, the aseptic filling method
upholds all the characteristics typical of a fresh product,
namely that its natural flavor and nutrients are retained
and no preservatives are required. The consumer profits
from a healthier product, the beverage industry from savings
for additives, and retailers from the longer shelf life
of the goods they sell in this segment, this being at least
21 days to up to 90 days in the cold chain, depending on
the product.
Beverage producers benefit from less complicated
ESL processes, coupled with flexibility. Whereas aseptic
filling systems regulate themselves fully automatically and
trigger a stop with even the tiniest discrepancies in processing,
the rules for ESL are not quite as stringent. The resulting
greater radius of operation and increased responsibility
of the operating personnel are supported by KHS
providing extensive training on the machine.
As a rule, operators attend a training course at KHS’
plant in Bad Kreuznach, Germany, shortly before the machine
is completely assembled. They are first taught the
theoretical basics and then trained on their machine,

Innovation
ABOVE — The Innofill ESL: perfect for products that
are sold through the cold chain.
Right — Neck ring guide: works with the utmost precision.
giving them a feel for the system and an understanding
of how hygienic bottling works. This intensive, individual
support from KHS is naturally continued once the line has
been commissioned, the full expertise of KHS’ engineering
staff being provided throughout the machine’s entire
life cycle.
Model Innosept Asbofill ABF
Two types of ESL machine are also available (see In brief)
based on the Innosept Asbofill ABF series of aseptic machines
that had the beverage industry worldwide convinced
within a very short time. A TWIN version of both of
these ESL setups is also available, giving customers twice
the capacity at a lower cost compared to investing in two
single machines. This is because a large number of the
components in the TWIN concept are required just once,
including chiefly the valve manifold, machine cladding,
operator terminal, controller, product and steam supply,
and downstream bottle conveyor. This reduction in the
number of components makes the system much smaller;
compared to the aseptic series it is around 15% shorter.
Another key factor is that KHS has specifically developed
the new Innofill ESL series using the expertise gleaned
from its tried-and-tested Innosept Asbofill ABF aseptic filling
equipment. Plants that already use an Innosept Asbofill
ABF and invest in an additional ESL thus profit from shorter
training periods for their personnel.

competence 01.2013 22/23
In brief:
the Innofill ESL
In focus Innofill ESL 611 Innofill ESL 711
There are three major differences, however:
1. Exceptionally small sanitary room on the ESL. The
sanitary room of the ESL 611 takes up a mere 0.7 m³ of
space, while that of the ESL 711 occupies only 1.2 m³.
This is because linear technology is used and only the
bottle neck is in the hygienic zone. Sterile air is blown
permanently into this area and discharged and extracted
downward through a perforated plate by a positive
displacement current. A valve manifold located at the
machine prepares the sterile air.
2. Simpler, more reliable sanitizing of the ESL machine.
The inside of the entire hygienic zone on the Innosept
Asbofill ABF always has to be sanitized prior to production.
The sanitizing cycle on the ESL only involves
the filler and capper area which could become soiled
with product. Cleaning with foam and gel reliably
reaches all areas in the filler/capper section.
3. Fast container sanitizing. As is usual in ESL processes,
low kill rates of approximately log3 are obtained during
container surface treatment thanks to shorter exposure
times when containers are treated with a sterilant
such as hydrogen peroxide. The Innosept Asbofill
ABF in contrast achieves higher kill rates of up to log6.
To sum up, with its Innofill ESL innovation KHS is closing
the gap in the bottling of ESL products, giving the industry
the technical system it wants: one that is flexible, compact,
and easy to operate. The very small sanitary room
also saves considerably on resources, thus cutting costs.
Simply cool!
Products
All plastics (such as PET, HDPE, PP, and PE).
All bottle shapes including oval, square, and rectangular.
Packs
All plastics (such as PET, HDPE, PP, and PE).
All bottle shapes including oval, square, and rectangular.
Output
12,000 bph
0.1 to 0.75 liters
12,000 bph
0.25 to 2 liters
A TWIN version is also available for both models
with an output of 24,000 bph.
Bottle diameters/
heights Up to 85 mm /240 mm Up to 120 mm /350 mm
Key functions/benefits
Conveyor
Cell support bars for reliable guidance
Surface
Fast bottle sanitizing (log3)
treatment
Sanitary room Very low volume thanks to linear technology and
small hygienic zone (saves energy, water, detergents,
and sterilants)
0.7 m³ 1.2 m³
Filling process In a separate housing
No valve contact – maximum hygiene /
low oxygen filling / minimum foaming /
volumetric filling – precise amounts, no overfilling
Automatic Filler and capper area
sanitizing
Capping
In a separate housing
Seals or screw caps possible / plastic
bottles sealed fully automatically
→ Contact
Optional
Thomas Niehr
KHS GmbH,
Bad Kreuznach, Germany
Paul-Uwe Winterhoff
KHS GmbH,
Bad Kreuznach, Germany
Phone: +49 671 852 2900
Email: thomas.niehr@khs.com
Phone: +49 671 852 2902
Email: paul-uwe.winterhoff@khs.com
Chunk filling
Separate doser upstream of the classic filling station
Piston filling with a low shearing stress – no
damaged solids / optional filling
of liquids and/or chunks / free-flow
filling system can be omitted

Innovation

competence 01.2013 24/25
The BIG
mini system
This is what the industry has been waiting for: an enclosed, highly efficient
housing for bottling water in PET under ultraclean conditions /
The new mini hygiene housing from KHS is not only compelling with its
compact design; it also saves time, space, and money.
The standard to date when filling water into PET bottles
under ultraclean conditions was the glass hygiene
housing that is open towards the floor. With the new mini
hygiene housing KHS has now met an important demand
of the industry, with the filling area in the mini hygiene
housing on stilts and enclosed, thus protecting it from all
external influences. Its consistent hygienic design not only
allows quick and efficient machine sanitizing; it also reduces
the amount of water and detergents used and saves
space (see In brief on page 27).
The other components in this innovation – the monoblock
concept, the Innofill NV filler, and the Innofill SV-ACF
capper – also prove convincing with their sophisticated,
tried-and-tested KHS engineering, complete with all the
benefits these entail.
The monoblock concept: hygienic and
corrosion-protected
The technology: after the stretch blow molding process,
the bottles pass through an airlock that reliably separates
the dry stretch blow molder from the wet filler. HEPA or
High-Efficiency Particulate Air filters permanently flush
the transfer stars that lead to the filling area with sterile
left — Filling valves in the mini hygiene housing.
Above — The filling valve control is located above
the ultraclean area.

Innovation
air. Parallel to the bottle guide a second flow of sterile air is
directed towards the capper and bottle discharge. A constant
level positive pressure is maintained inside the mini
housing, with the air removed through strategically positioned
openings in the upper and lower area of the machine
created by the overlap of the machine carousel and
static components. A recommended option is to extract
the sterile air when bottling ozonic water.
The benefits: as the dry area of the stretch blow molder
is systematically separated from the wet area of the filler,
the stretch blow molder is not subject to corrosion. The
entire bottle transfer area is permanently protected by a
blanket of sterile air.
The Innofill NV filling system:
flexible and proven
The technology: the system fills different sizes and
a mounts through a non-contact, free-flowing filling valve
→→
from 0.1 to 3-liter bottles
→→
from 15,000 up to 72,000 containers per hour
→→
with various types of mouth and closure.
All this happens without bottle mouths being sealed or
pressed against the filling elements and without contact
with the valve components. Tried-and-tested volumetric
impeller flow metering is used as the system of measurement
and based on the volumes of liquid transported in
the impeller areas, with the signal transmitted without
contact to a sensor. Alternatively, the flow can also be metered
by electromagnetic induction.
Three questions for …
… Ludwig Clüsserath, manager of Filling and
Processing Technology Development at KHS.
The benefits: the entire filling process gives users maximum
microbiological and hygienic safety. The valve components
do not come into contact with the bottle opening,
which means no product wetting and no dripping.
Signals are transmitted without contact to an inte grated
sensor using volumetric impeller flow metering. Impeller
flow metering also enables demineralized water to be
filled that does not have a significant measurable level of
conductivity.
Which customers will profit from the new mini hygiene housing?
In principle all of them. For competitive reasons, among others, the trend in mechanical
engineering is towards increasingly more compact, highly efficient, and
thus cost-effective equipment across the various branches of industry. The focus
here, however, is on filling technology where the stretch blow molder and filler are
monoblocked and microbiologically sensitive products are to be bottled.
More and more, customers are looking for variable, flexible machinery.
Which options does the mini hygiene housing offer?
Lots. For example, the mini hygiene housing can also be used where bottles are fed
in by an air conveyor. With the monoblock concept customers can also choose between
various systems for filling and capping.
What has initial experience in practice been like?
Very good. The mini hygiene housing does what it promises to do: the savings in
space, servicing periods, air, and detergents are really impressive. I’m not exaggerating;
our customers are very enthusiastic!

26/27
The Innofill SV-ACF closure system:
user friendly and reliable
The technology: the computer-controlled servo screw
capper processes many types of cap, strictly and hygienically
separating rotational and vertical movements. Only
the parts actually needed for the capping procedure are
included in the sanitary room. The cleaning nozzles integrated
in the mini hygiene housing reach the transfer
stars, filling valves, capper elements, and all interior surfaces.
The transfer stars, filler, and capper have separate
servo drives located in hygienically designed columns outside
the housing.
The mini hygiene housing
in brief
Closed base
Facts
Benefits for bottling plants
+ No outside influences
The benefits: the hygienic design of the entire machine
enables fully hygienic capping and cleaning. Glass doors
make the system transparent, quick to access, and simple
to operate for cleaning and maintenance purposes.
→ Contact
Ludwig Clüsserath
KHS GmbH,
Bad Kreuznach, Germany
Klaus Baumgartner
KHS GmbH,
Bad Kreuznach, Germany
Phone: +49 671 852 2501
Email: ludwig.cluesserath@khs.com
Phone: +49 671 852 2291
Email: klaus.baumgartner@khs.com
Compact machine design
Hygienic design
KHS operator console with
an RFID system
+ 30% less space needed
+ Cost advantage I
+ Extremely hygienic filling
+ Fast, efficient cleaning
+ Reduced detergent use
+ Less air used
+ Cost advantage II
+ Self-explanatory navigation
+ User-friendly ergonomics

Innovation
The top
performers
KHS palletizing technology for high capacities
is state of the art / It’s like sports: you only get
top results when you’ve got the best players to interact
perfectly with one another. What’s behind
KHS palletizing technology.

28/29

Innovation
When it comes to palletizing, the companies in the
beverage and food industries are rather demanding.
Containers made of glass, PET, and metal have to be
perfectly packed and palletized when they are shipped to
the retailers. The packaging machinery that performs this
task also has to be increasingly flexible as consumer demands
are changing ever faster. And that’s just the beginning.
The machines of course also have to work extremely
reliably at a high level of availability – and also be quiet,
sustainable, gentle on materials, low on space, and easy
to operate and maintain. KHS has been meeting these
complex customer requirements for decades – with a policy
of continuous improvement and the technological innovations
that result from this. And that in all segments,
namely for low, medium and top palletizing capacities.
In the following article KHS competence presents the top
performers in its range of palletizers with their various
strengths and areas of application: the Innopal RC robot
combiner, the Innopal RK 4 robot, and the Innopal PB 1
HS gantry palletizer. These three machines have simply
got what it takes.
1
High-performance secondary packaging (I):
the Innopal RC manipulates the packs ...
The task: primary packaging is often packed in secondary
packaging. For example, film-wrapped packs of eight
containers each are formed in a primary packaging machine.
In a second machine three of these packs are then
turned into a tray of 24 and packed with or without film.
If the discharge situation at the first packer does not coincide
with the infeed at the second machine, the packs are
manipulated accordingly by an Innopal RC. Another scenario
could be that different formats have to be turned
into wrap-around packs, some of which then pass through
other packers.
The system: the Innopal RC four-axis robot combiner handles
loads of up to 40 kg. Its head consists of a parallel gripper
that can be set to between 80 and 400 mm by servo
motor. Depending on the capacity and products to be processed
parallel grippers of between 600 and 800 mm in
Above — The Innopal RC positions the packs
and places them on the designated lanes.
Below — Stacking inspected pallets in the
empty pallet magazine.
length are used. Built into a table setup mounted above the conveyor
segments, the parallel gripper has direct access to all discharged packs
and moves them either individually or in units into the designated
number of lanes, maintaining a specified distance between the packs.
The benefits: the systems with integrated pallet distributors used to
date are now largely no longer needed, thereby reducing the amount
of space, maintenance effort, and number of parts and spare parts
required. What’s more, the guard rails at the infeed and the Innopal
RC are automatically reset to the new format by simply selecting the
appropriate program.
2
High-performance secondary packaging (II):
... and places them on the designated lanes
The task: to feed products from several packing lines to one palletizing
center.
The system: the Innopal RC is installed upstream of a palletizing center
and distributes the packs into the palletizing infeed lanes. A robot
grouping (RG) assigned to the palletizer forms the packs into layers
(the same type of robot is used as on the RC) so that they can be palletized.
Here, the following rule of thumb applies: there should be one
Innopal RC robot combiner per palletizer in the line. This means that in
high-performance palletizing centers there are usually two. They operate
as on the individual packaging lines, pushing the products into
the relevant lanes.
The benefits: besides the plus points mentioned above, manipulating
the packs as described enables extremely flexible palletizing, including
the formation of mixed pallets. Each packaging line can also be individually
assigned to one or both palletizers.

competence 01.2013 30/31
KHS event:
We robot!
Around 150 experts from all over the world came to Worms,
Germany, where KHS staged a special robot palletizing event for guests
from the beverage, food, and non-food industries.
The highlight was the live presentation of a highly flexible palletizing
system for cans which KHS had specifically manufactured for a customer.
The precise interaction of various robot groups on the high-performance
line processes over 120,000 cans per hour in various packs
on several lanes using robot combiners. The practical demonstration
elicited the desired positive response. “We’re getting
a fantastic live impetus for future concepts here,”
enthusiastic participants reported.
“A fantastic
impetus
for future
concepts”

Innovation
The pallet cleaning station
is part of the customized concept.
Top capacities
are doable
Task
Machine
Result
Task
Machine
Result
Task
Machine
Result
Task
Machine
Result
Task
Machine
Result
Task
Machine
Result
Manipulation of small packs
Innopal RC
Less space, fewer parts, less maintenance needed
Distribution of pack flows
Innopal RC
Individual allocation to specific palletizers
Pack grouping
Innopal RG
Fewer parts and faults, lower cost, less space,
and maintenance required
High output of stable pallets
Innopal PB 1 HS
Up to 600 layers per hour, with up to 750 layers
per hour optional
Handling of different pallets
Innopal RK 4
Fewer peripherals, savings in space and money
Constant supply of pallet liners
Two pallet conveyor systems
Continuous availability of pallet liners
3
High-performance inline robot grouping:
the Innopal RG for perfect, flexible grouping
The task: the packs positioned on the allocated lanes are
to be grouped for palletizing.
The system: with two infeeds – which is standard for flexible
high-performance lines – two articulated four-axis
robots prepare the layers with the utmost precision. The
head consists of a parallel gripper that can be automatically
set to widths of 80 to 400 mm by servo motor. Depending
on the capacity and products to be processed parallel
grippers with lengths of up to 800 mm are used. For reasons
of safety the pivot angle is restricted by mechanical

competence 01.2013 32/33
5
limit stops in robot grouping stations and the combiner;
despite this, all positions can be exactly set by the pushing
motion and perfectly adapted to the speed of the plastic
mat top chains. Before being transferred to the palletizer
pushover plate the layer is centered.
The benefits: pack manipulation elements such as turning
stations or gap splitters are no longer required; neither
are reconfigurations for new formation requirements or
investments in additional manipulation elements. This cuts
costs. The inline robot grouping also handles packs gently,
is very flexible, and reduces the amount of space needed
for equipment. Thanks to the use of robot technology the
grouping station is practically maintenance free; sources
of error, such as undesired pack turning, are also no longer
an issue.
4
High-performance palletizing (I):
the Innopal PB 1 HS for fast, gentle palletizing
The task: high palletizing outputs, stable pallet loads, perfect
layer formations.
The system: the fully automatic Innopal PB 1 HS gantry
palletizer with a split pushover plate operates with a pallet
lift, feeding packs from above. The split pushover plate
opens, places each layer directly onto the pallet, and closes
again after the pallet has been lowered. The layer pusher
then slides the next layer onto the pushover plate. Automatic
all-round centering gives customers perfect layer
formations and a high overall pallet load stability. When
processing packs that are not very stable, an additional
centering device can be integrated into the machine below
the discharge plate as one of two options; the other
is for the customer to invest in a twin pushing mechanism.
The benefit: the standard version of the machine is able
to process up to 600 layers per hour. When using a twin
pushing system there are no delays which naturally occur
when a single pusher system is retracted, and the output
increases to up to 750 layers per hour.
High-performance palletizing (II):
the Innopal RK 4 processes the widest range of formats
The task: to supply the palletizer with controlled full, half, or quarter
pallets.
The system: KHS equips the system with a second four-axis Innopal
RK 4 robot which can process loads of up to 180 kg. Its fully automatic
head system picks up various types of pallet with the utmost flexibility.
This robot is a pallet handling robot which takes the empty pallets
fed to the line from a pallet dispenser and conveys them to a pallet inspector.
Following inspection the pallets are again picked up by the robot
and either placed on the supply segment of one or two palletizing
machines or magazined if they are faulty. The Innopal RK4 can access
all of these areas within a 360° radius, working through its list of tasks
according to given priorities.
The benefits: many of the peripherals common to the classic setup are
not needed here, such as conveyors and manipulation elements, saving
both space and money.
→ Contact
Hans-Werner Holzer
KHS GmbH, Worms, Germany
Michael Rapp
KHS GmbH, Worms, Germany
6
High-performance palletizing (III):
fully automatic system for pallet liners
The task: high-performance palletizing in particular requires a constant
supply of pallet liners.
The system: here, two pallet conveyor systems have been arranged
as a double deck. Depending on the plant’s individual requirements
there are several pallets of pallet liners on the top deck, with the one
in the dispenser being processed first. These pallet liners are moved
within reach of the pallet liner inserter by the pallet lift and exactly positioned
by a four-sided, pneumatic centering unit. A linear handling
robot then grasps the liners and places one on the product pallet after
each formation has been discharged. When the pallet liner pallet is
empty, it is moved down to the lower conveyor segment and ejected
from the system. The next pallet liner pallet then enters the dispenser,
and the process continues without interruption.
The benefits: the palletizer is supplied with pallet liners just in time independent
of forklift availability.
Phone: +49 6247 97 3351
Email: hans-werner.holzer@khs.com
Phone: +49 6247 97 3293
Email: michael.rapp@khs.com

Innovation
Airback Plus
Improved technology saves up to 40% compressed air / The InnoPET Blomax
generations are now even more sustainable – and offer
considerable cost reductions, as practical experience has already shown.
Airback I
Airback Plus
Airback Plus :
recycles up to 40%
of the compressed
air used.
10 %
30 %
P1 phase:
pre-blowing
P2 phase:
blow molding
Among its many concerns KHS Corpoplast
has one very important aim: to continue
improving its technology – for the immediate
benefit of its customers. One of its many endeavors
is to cut down on the amount of materials,
energy, and compressed air consumed
by the InnoPET Blomax Series III and IV stretch
blow molders it successfully launched to market
several years ago. This has always been
its guiding principle, recently honored by TÜV
SÜD presenting the concept with an award
(see page 89).
1. The Bottles & Shapes program developed
by KHS Corpoplast optimizes bottle performance
and thus reduces manufacturing
costs, for example through the use of lightweighting
and/or by reducing the blowing
pressure from the usual 35 bar to approximately
28 bar.
2. With the introduction of the Series IV
the amount of compressed air used sank yet
again, with the new Eco-Space high pressure
valves used in conjunction with a modified
valve block reducing what’s known as the
dead space by a further 30% compared to the
previous generation.
Finished
bottle
Next bottle
on the blow wheel

competence 01.2013 34/35
Sample calculation:
cost-cutter Airback Plus
The following practical example that assumes just 36% less
compressed air is used illustrates how much money can be saved
using Airback I and Airback Plus .
3. Besides the amount of compressed air
required per blow molded bottle, what also
counts is how much of this compressed air can
be reused. During the pre-blowing phase the
Airback I air recycling system first developed
by KHS Corpoplast saves around 10% of the
compressed air consumed at this stage.
4. With the Airback II system the highpressure
blowing air already used is extracted
from the machine and fed to the customer’s
supply or straight to the compressor. This reduces
the energy consumption by up to 20%.
THE STARTING POINT
→→InnoPET Blomax Series IV stretch blow molder,
type 16 S (16 blow stations)
→→35,200 1.5-liter PET bph (2,200 bottles per cavity)
→→Blowing pressure: 28 bar
→→Compressed air used to date: 1,680 m³/hr
→→Compressed air used with Airback Plus : 1,075 m³/hr
→→Production hours: 5,000 per year
→→Energy costs: €0.10 per kWh
THE RESULT
→→1. Compressed air
Reduced compressed air consumption
600 m³/hr
Energy saved (0.2 kWh per m³)
121 kWh/hr
Saving per year (at 5,000 production hours) 605,000 kWh
Costs saved (at just €0.10 per kWh)
€60,500 per year
→→2. Compressor
Reduced investment costs of up to approx. €70,000
Cost savings per year of up to approx. €4,000
(spare parts/maintenance)
RETURN ON INVESTMENT (ROI) BASED ON THIS CALCULATION:
APPROXIMATELY 1 TO 1 1/2 YEARS.
5. The Airback Plus innovation reuses the highpressure
blowing air from the machine’s internal
blow molding process to manufacture
the bottles. Combined with Airback I, savings
of an impressive 40% maximum are possible.
In addition, with a new investment less investment
capital is needed for the compressor,
with reduced maintenance and spare parts
costs the result.
Good to know: Airback Plus can also be retrofitted
into existing InnoPET Blomax Series IV
and InnoPET Blomax Series III stretch blow
molders, considerably reducing manufacturing
costs. This way, investment pays off within
a minimum amount of time (see the sample
calculation).
What’s more, in the future Airback Plus will
undoubtedly be very welcome in countries
where the amount of energy available is limited
or where energy costs are very high.
The chief benefits
→→
Costs are saved through a more efficient
use of energy
→→
Competitiveness is increased thanks to
optimized production conditions
→→
The carbon footprint is improved by
high savings in energy.
To sum up, in launching Airback Plus KHS
Corpoplast has taken another significant
step towards sustainability and reducing
production costs – with plenty of extra benefit
for their customers. This has been impressively
verified by the first practical experience
gained with this new system.
→ Contact
Frank Haesendonckx
KHS Corpoplast GmbH, Hamburg, Germany
Phone: +49 40 67907 475
Email: frank.haesendonckx@khs.com

Market report
Market report
Customer projects and KHS acceptance tests around the globe

competence 01.2013 36/37
Coca-Cola ThaiNamthip, Thailand
KHS hotfill line
proves convincing
ThaiNamthip, currently the largest bottler
of Coca-Cola brand products in Thailand,
recently took delivery of a KHS hotfill line for its
largest plant in Rangsit, Bangkok. The new line
processes Minute Maid, primarily the Pulpy
and Nutriboost varieties. With annual growth
rates of around 50% the fruit juice brand is becoming
more and more popular in Thailand.
The HotFill+ system functions as part
of an InnoPET BloFill monoblock concept
where nitrogen is fed into the headspace of
each PET bottle after filling. The benefits:
→→
No vacuum in the bottles
→→
Vacuum compensation panels are
superfluous
→→
Much lighter bottles with the same
bottle stability can be used.
The 290-ml Minute Maid Pulpy bottle thus
weighs just 18 grams, with the 335-ml size
at 19 grams, and the 280-ml Minute Maid
Nutriboost bottle at 23 grams based on a required
minimum wall thickness.
Cherdsak Srikittiphun, product manager
at ThaiNamthip, says proudly, “With this
system we’re pioneers in Asia. Using innovative
technology has definitely paid off for us.”
ThaiNamthip is also profiting from the KHS
Bottles & Shapes program. The partners developed
the Minute Maid bottles specifically
for the HotFill+ system together. The result:
→→
Many different bottle designs possible
→→
Much less bottle material required
thanks to the lighter weight.
The KHS InnoPET BloFill monoblock concept
has of course also convinced ThaiNamthip,
operating as it does without any air conveyors
and rinsing systems and making long-term
savings in energy and water. KHS’ innovative
packaging and palletizing technology has
also been enthusiastically received. Cherdsak
Srikittiphun sums up. “The entire KHS concept
has convinced us with its outstanding engineering
and top-quality service.” Thai Namthip then
went on to demonstrate its trust in top technology
from KHS by ordering a second HotFill+ line
which will be installed in 2013. Making investments
like these will allow the company to secure
its excellent market position with its seven
production sites and a turnover of over 250 million
unit cases or about 1.4 billion liters per year.
www.thainamthip.co.th
Marston’s, Great Britain
A question of the
right system
Traditional brewery Marston’s PLC in
Burton-upon-Trent in the east of Staffordshire
has been brewing its famous tipple
(the best known being Marston’s Pedigree
cask ale) according to the unique Burton
Union System since 1834.
The company’s brewing expertise is obviously
being excellently received by consumers,
with Marston’s now wanting to meet the
growing demand with a new one-way bottling
line from KHS which will process 18,000 0.5-
liter bottles per hour. The chief components
include: an Innopro CORVUS BMF90 membrane
filter / an Innopro KZE flash pasteurizer
/ an Innopro CIP cleaning-in-place system
/ an Innopal AS1 N depalletizer / an Innofill
Glass DRS-ZMS bottle filler / an Innoket KL
2000 labeler / an Innopack Kisters WSP wraparound
shrink packer / an Innopal PBL palletizing
robot.
The new line fills various bottle sizes: 275,
330, and 500 ml. Shorter changeover times are
also giving the brewery much greater flexibility.
www.marstons.co.uk
Bralima (Heineken), DR Congo
Technology for
hot zones
Bralima, the largest brewery in the Democratic
Republic of the Congo, has again invested
in extremely robust machine engineering
from KHS as the company, which is part of
the Heineken Group, operates its plant under
extreme conditions. Bralima is combining its
existing beer and soft drinks lines into a largely
refurbished glass returnable line in Kisangani
in the north of the republic where in the future
it will bottle beer and carbonated soft drinks.
Here, it will use an older yet proven KHS filler
and a Paramix setup. The combined line will
also include new craters and decraters, a pasteurizer,
a double-end bottle washer, and modern
conveyors.
The investment is yet another chapter in the company’s
story of successful growth – and proof of
its trusting partnership with KHS. At the plant in
Kinshasa similar KHS machines are already giving
Bralima the best performance. The highlight
of the new lines is that they will use considerably
less water and energy – both top issues for a
company that operates in such a hot zone.
www.bralima.net

Market report
Abdel Hadi Abdallah Al-Qahtani & Sons, Saudi Arabia
Another milestone
As one of the four largest Pepsi bottlers
in Saudi Arabia Al-Qahtani Beverages
(AQS) supplies the southeast region of the
country. Its chief products are carbonated soft
drinks or CSDs, the range of which includes
Pepsi-Cola, 7UP, Miranda, and Shani. The company
has now ordered a second 90,000-cph
line from KHS which will process cans holding
150, 250, 355, and 500 ml of all products in
the Pepsi portfolio.
What’s special here is that besides packing
typical big packs of 24 and 30 cans the
line must also be able to produce six packs of
the 355 and 500-ml can. The range of packaging
– from the simple film shrink pack to
the pad-and-film combination to trays – calls
for the utilization of KHS’ flagship packer the
Innopack Kisters TPFO tray shrink packer, a
real all-rounder. The products are grouped
and layers formed by two fully automatic articulated
robots which save lots of space, operate
with the utmost efficiency even at high
outputs, and enable a huge range of different
formations, especially regarding small pack
formats such as the classic six pack.
The new canning line will replace an older,
lower capacity system. It was a great feat for
all concerned to accommodate the sophisticated,
ultramodern, high-performance line
on site – a feat only made possible by the
line’s very compact design and by extending
the existing production shop to include
two additional segments. Besides providing a
range of greatly optimized functions the KHS
canning line enables the company to process
a much larger spectrum of products, container
types, and pack formations, and also to hot
fill sensitive beverages.
For many years now KHS has been the
system supplier of choice for Saudi Arabia’s
very well-known Pepsi franchiser. The first
milestone to help boost the company’s output
was a high-performance 90,000-cph line
from KHS installed at AQS in 2005. The plant’s
main area of business is and always has been
the sale of soft drinks in cans. In 2010 a modern
bottle washer was purchased for an existing
glass line. This recent investment is a second
milestone in the history of AQS.
Kaiserdom Specialitäten Brauerei, Bamberg, Germany
In focus: the 1-liter can
One of KHS’ long-standing customers,
Kaiserdom Specialitäten Brauerei in the
Franconian city of Bamberg, has just ordered
a volumetric can filler that outputs 0.25 to
1-liter cans. KHS has integrated the filler into
an existing line so that it can now process various
lids at a nominal capacity of 35,000 cans
per hour.
Kaiserdom not only produces various sizes
of can; its range of products also includes
two special 1-liter cans. KHS has many reference
applications such as these to its name,
with similar setups installed in Eastern Europe
where the 1-liter can is very popular. The new
filler improves production, has shorter setup
times, again improves hygiene quality, and at
the end of the day gives Kaiserdom greater
sustainability thanks to lower overall costs.
With an export share of over 50% the brewery
is represented in over 40 countries of
the world, such as Australia, China, Korea,
the USA, and Canada. The company acts as
a contract filler for many German brewery
groups and companies, reflected in its extremely
innovative and interesting spectrum
of products. A KHS filler is also used to process
bottles. Founded in 1718, Kaiserdom
evolved from the brewery run by the Benedictine
monastery of St Michaelsberg.
www.kaiserdom.de

38/39
Sheikh Zayed Road: Dubai’s skyscrapers pierce the night sky.
Dubai Refreshment Company, United Arab Emirates
Perfect lines
The Pepsi-Cola franchise Dubai Refreshment
Company (DRC) has again opted
for two high-performance lines (can and PET)
from its long-term supplier KHS.
PET line
→→
Products: carbonated soft drinks in the
Pepsi product range and still mineral
water (Aquafina, for containers holding
up to 2.25 liters)
→→
Capacity: 40,000 0.5-liter nonreturnable
bottles
Canning line
→→
Products: cold filling of soft drinks and
hot filling of iced tea (Lipton)
→→
Output: 90,000 355-ml cans for soft
drinks or 45,000 320-ml cans for Lipton
iced tea.
DRC’s demanding specifications included the
ability to process a wide range of products,
flexible processes (hot and cold fill products,
highly carbonated to 10 grams of CO₂ per liter),
and processing of non-carbonated beverages.
It also wanted a high degree of automation,
a performance buffer of up to 40%
overcapacity in the packaging area, and hygienic
preparation of the lines for the future
filling of sensitive products (Aquafina on the
PET line and mixed juice beverages on the canning
line). The impressive product portfolio
includes Pepsi-Cola, Pepsi Diet, Pepsi Max, Miranda
Vitamin C, Miranda Green Apple, Miranda
Citrus, Mountain Dew, 7UP, 7UP sugar
free, Everess, Lipton Ice Lemon, and Aquafina.
KHS spent over a year developing the
best tailored line concept together with the
client. The result? Two lines which perfectly
meet all of DRC’s requirements. Automatic
filling and cleaning processes in the filling
area ensure perfect product quality, for example.
For sensitive beverages the parts of the
machine which come into contact with the
product are designed in especially high-grade
stainless steel (AISI 316L). The packaging section
with its packing robots operates fully
automatically at high capacity to produce
an enormous range of different packs. And
the cooler on the canning line for hot filled
iced tea, for instance, could even function as
a pasteurizer in the future. You couldn’t ask
for more perfection and flexibility from a filling
line. What’s also notable is that DRC has
been a KHS customer since 1979. The Pepsi-
Cola franchiser, which started out as a small
beverage processing company in Dubai City
in 1962, has already invested three times in innovative
high-performance technology from
KHS. After all, a perfect company needs perfect
lines ...
www.pepsidrc.com
Birra Castello, Italy
KHS for the
first time
Birra Birra Castello in S. Giorgio di Nogaro
in Udine is heralded as one of the most
modern breweries in Italy. The fast-growing
company has just invested in technology
from KHS. Very soon an up-to-the-minute
KHS canning line for beer and a KHS Innopas
PII SC tunnel pasteurizer are to go into operation
in a new building, with a capacity of
96,000 0.33-liter cans per hour. According to
the management at Castello the main reasons
for this decision were KHS’ outstanding international
reputation for first-class filling technology,
and especially for high-performance
canning lines, premium KHS pasteurizing
technology, and the many impressive system
layouts it has installed to date.
With the new setup the group aims to
reach several important targets for its production
of around a million hectoliters of beer
per year, namely:
→→
To meet the growing demand for beer in
cans (a plus of 15% in the last two years)
→→
To noticeably improve the efficiency of
canning
→→
To further improve the quality of its
filled products
→→
To increase packaging flexibility
→→
To cut costs for personnel, energy, and
water,
→→
and to avoid a third night shift.
It’s interesting to note that in 2008 Birra Castello
was the first brewery in Italy to be certified
according to the International Food
Standard (IFS). It’s thus easy to understand
why the company wants to safeguard the
top quality of its products using cutting-edge
technology from a leading manufacturer.
www.birracastello.it

Market report
Saudi Industrial Beverages Co (SIBCO),
Saudi Arabia
New standards
The Saudi Industrial Projects Company
(Pepsi Cola Bugshan) is merging its three
production sites to make one new plant and
in the future will change the company name
to Saudi Industrial Beverages Co (SIBCO). The
new megaplant occupies a 300,000 m2 plot
(or fifty soccer fields) in the recently opened
Second Industrial City in Jeddah. The company
wants the plant to meet the highest standards
and set new ones with regard to energy
efficiency, hygiene, and logistics. When finished
in 2017 it will output up to 3.4 billion
containers (returnable and non-returnable
glass bottles, cans, and PET bottles) or two billion
liters of product (chiefly Pepsi-Cola, 7UP,
and Aquafina) a year.
KHS has been awarded the contract to
supply several complete lines for the new
plant for filling Pepsi products in cans and
glass bottles, and also packaging machines
for PET bottles (start of production: January
2014) as follows:
→→
Three canning lines for 355-ml cans
(90,000 or 120,000 cph)
Riad: the pulsating capital of Saudi Arabia with a population of 4.6 million.
→→
A glass line for 300-ml returnables and
non-returnables (60,000 bph)
→→
Three packaging lines for CSD PET lines
(42,000 and 48,000 bph)
→→
A packer for the Aquafina PET line
(56,000 bph).
KHS will deliver these customized lines according
to the state of the art regarding energy
efficiency, degree of automation (ERP,
raw materials feed, full bottle/can handling),
line efficiency, environmentally friendliness,
ease of operation, hygiene, and occupational
health and safety. What helped win KHS
the contract is that in the past few years
KHS has provided SIBCO and other customers
in the kingdom of Saudi Arabia with
high-performance canning lines with an efficiency
of over 95%.
SIBCO belongs to the Ahmed Salem
Bugshan Group which in turn is part of the
Mr. Abdullah Said Bugshan Group, the latter
founded over 60 years ago. The group is one
of the top ten company groups in Saudi Arabia
and is active in over 20 fields of business
worldwide. These areas of activity include
the beverage industry (with Pepsi-Cola franchises
in Saudi Arabia, Egypt, and Yemen),
crude oil exploration, hotels, hospitals, insurance,
logistics, port operations, banking, real
estate, and steel manufacture.
www.asb.com.sa
Compañía Cervecera de Nicaragua,
Nicaragua
Turnkey line
Compañía Cervecera de Nicaragua (CCN)
in Managua, Nicaragua, recently opted
for a high-performance turnkey canning line
for beer from KHS for the very first time. The
line is able to fill 45,000 12-ounce cans per
hour, and also processes 8 and 16-ounce containers.
It has been designed so that it can also
manage 10 and 24-ounce cans in the future.
Further special features include the volumetric
Innofill DVD 60 with a very low
CO₂ consumption and state-of-the-art Innopack
Kisters packaging machines that
can process nested shifted packs and are
equipped with a resource-saving, gas-powered
eco shrink tunnel. As a turnkey supplier
KHS will install the entire system including
all necessary services, up to and
including the training of CCN personnel.
3D technology was used at the planning
stage.
CCN was founded in 1926. The company
merged with its long-term competitor Industrial
Cervecera (ICSA) in 1996, and is now
the largest brewery in Nicaragua. In 2002 the
brewers branched out into the bottled water
business with their Agua Pura brand, soon
also producing juices and sports drinks. CCN
has been exporting beer to the USA since
2003. This is a success story and KHS partnership
with tradition.
www.ccn.com.ni

competence 01.2013 40/41
Oskar Blues Brewery, USA
Modern and
robust
SABMiller Kompania Piwowarska, Poland
All good things
come in threes
Pepsi Domodedovo, Russia
New line –
new market
Oskar Blues Brewery in Longmont, Colorado,
is one of the USA’s small but fastgrowing
craft breweries. Its growth and success
mean that the demands made of the
machines used by the company are also growing.
The management wants technology that
is both modern and robust, thus opting for
a supplier who is well known in the American
brewing industry: KHS. Within the shortest
possible period Oskar Blues took delivery
of two new Innofill DMD 30 canners for its
plants in Colorado and North Carolina, with a
capacity of 16,800 355-ml cans per hour. The
mechanical construction is extremely robust,
providing the brewery with reliable, proven
technology built and supported by the KHS
plant in the USA. The machines require minimum
maintenance and are running with
no downtime. One of the chief features that
Oskar Blues appreciates most is the very low
oxygen pickup in the product.
SABMiller Kompania Piwowarska (KP)
in Białystok, one of the biggest Polish
brewery groups in the largest city in the
northeast of the country, is soon to install a
new packaging system for multipacks. Or to
be precise, a KHS Innopack SP-AM to pack
loose cans into shrink packs of four and six.
The shrink packs will then be placed on trays
or sent straight to the palletizer. Thanks to
the good experience the company has had
with packaging lines and film shrink systems
from KHS, in the past 15 months KP
invested in its third packaging line as part
of a KHS canning line.
KP demanded high standards for its disposable
packaging in particular which KHS
was able to surpass. KP's new Innopack SP-
AM now gives it top efficiency with the best
packaging quality, gentle pack handling, fast
changeovers, great flexibility, easy access,
and ease of operation.
The die was cast at Brau Beviale 2012.
As one of Russia’s traditional market
leaders for alcohol-free beverages, juice,
and baby food the experts from Pepsi-Cola
Domodedovo were looking for the best technology
with which to diversify into a new field
of business. The Moscow company now wants
to penetrate the market for the local seasonal
Russian beverage kvass, a yeast-based bread
drink. Turkey supplier KHS, experienced in
kvass-processing technology, is now to deliver
a full PET line to the company, including
pasteurizing and CIP equipment, with a
capacity of 45,000 0.5-liter, 36,000 1-liter, or
24,000 2-liter bottles per hour. KHS will also
take care of the piping, cabling, media supply,
and turnkey installation and commissioning
of the machinery. The order is based on the
many years of positive experience Pepsi-Cola
in Russia has had with highly efficient turnkey
projects delivered by KHS to date.
www.oskarblues.com
www.kp.pl
The company headquarters in Moscow.
Distell, South Africa
KHS for the
fourth time
Distell, a leading South African bottler of
wine, spirits, cider, and sparkling wine,
has just ordered its fourth filling line from KHS
in the space of the last four years. The new acquisition
is a second 60,000-cph canning line.
Two bottling lines with the same capacity are
already in successful operation. For the older
of these glass lines, by way of an upgrade
Distell will also be receiving a blender, an
Innopro KZE flash pasteurizer, and a tray
shrink packer. The new line will also include
– and this is a first for the African market –
an Innopack Kisters SP-AH shrink packer for
FullyEnclosed FilmPacks. KHS South Africa
has enjoyed a good business relationship
with Distell for many years.
www.distell.co.za
www.pepsico.com

Service
Energy-saving bottle carriers
use up fewer resources and less energy.

competence 01.2013 42/43
The wind of change
Reinvest or bring old technology up to par?
/
Even systems that have worked perfectly for many years have to adapt to changing
market and technical requirements at some time or another. In many cases
it’s worth converting or upgrading to include the latest in technological advance.
Study the following top ten areas of production to see how it’s done.
balance sheet isn’t always a question
A of profit and loss. A successful history
of over 140 years manufacturing filling and
packaging equipment for the beverage industry
and 40,000 machines on the market
worldwide, with 40% of these in reliable daily
operation for over 15 years, is the proud balance
of KHS’ clear orientation towards its
customers worldwide. And of its long-term
company policy – and mission – of securing
customers an excellent competitive position
with innovative technology.
But what happens when consumer requirements
change, a beverage plant suddenly
mushrooms in size, boosting its output,
or machine technology has to be adapted?
Conversions and/or upgrades of existing machines
and lines, perfectly customized to the
specific requirements of the company, are often
the means of choice. In 80% of cases the
initiative is taken by the customer reacting
to changes on the market from experience,
whether these be higher demand, new products,
more modern containers, improved labels,
or higher standards of hygiene. KHS
Service personnel also constantly watch the
market, regularly recommending and discussing
possible technological upgrades and the
benefits thereof with customers in the course
of an intensive program of customer care.
The value of the resulting investments is
demonstrated by impressive sets of figures.
Each year KHS implements a number of conversion
projects both big and small in the
four-digit price range. The range of services
KHS offers – based on intensive, permanent
dialog with customers worldwide – is as varied
as the many products sold by the beverage
industry. Over the years a few bestsellers
have emerged among the upgrades
carried out by the KHS Service team active
around the world. The following gives
an overview of the top ten upgrades supplied
by KHS. Whatever the customer opts
for, the formula KHS works by is Upgrade
(new for old) = Technological Advance. This
also makes for a favorable balance for the
customer.

Service
Flow deflectors
in the shrink tunnel.
The Siemens S7 control:
converting to up-to-the-minute control technology.
The top ten: number 1
Control system technology upgrade
The situation: converting older systems is designed
to safeguard their operational reliability,
for example if suppliers terminate or
phase out the delivery of spare parts according
to contract.
The KHS offer: to replace the CPU (Central
Processing Unit), the heart of the controller.
This often also calls for the internal machine
wiring, sensors, and actuators to be changed.
The KHS Service experts write a new program
and configure it to match the functions of the
particular machine.
The result: the future supply of spare parts is
secured and the machine function and ease
of operation are improved.
The top ten: number 2
Bottle washer upgrade
The situation: older returnable glass lines
and bottle washers in particular consume a
lot of water and energy.
The KHS offer: a conversion package with
three modules: replacement of the steel carriers
and steel bottle pockets with energysaving
bottle carriers; integration of a fresh
water controller; retrofit of a power-saving
function for spray pumps.
The result: the plastic bottle pockets on the
energy-saving carrier reduce the carrier
weight and the heat and caustic carryover,
and save up to 15% in heat and up to 20% in
fresh water. In addition, less maintenance effort
is required and there is less bottle damage.
With its electropneumatic control valve,
corresponding flanged joint and connection
to the machine controller the fresh water
controller automatically adjusts the amount
of fresh water required for spraying to the
machine speed, thus also cutting water consumption
and costs.
The power-saving function for spray
pumps with its integrated frequency controllers
and adapted software is geared towards
the operating state of the washer, throttling
the machine speed during downtime
and restarting it quickly, saving considerable
amounts of steam, fresh water, caustic, and
additives.
The top ten: number 3
Pasteurizer upgrade (I)
The situation: in older pasteurizers what’s
known as the pilger step conveying system
causes discontinuous movement of the containers
during pasteurization.
The KHS offer: to remove the conveying system,
install new conveyor belts made of plastic
or stainless steel, complete with a belt bed
for the tight and return span, new drive units,
and idler shafts. The pasteurizer also receives
a modified tunnel, plus transfer parts for connecting
the infeed and discharge conveyors,
electrical parts in the control cabinet, wiring,
and a new, state-of-the-art pasteurization
program.
The result: more precise and much gentler
container conveying; noticeably reduced energy
and water costs, less effort for maintenance,
and fewer spare parts.
The top ten: number 4
Pasteurizer upgrade (II)
The situation: inferior product quality due to
thermal influences.
The KHS offer: to integrate dynamic PU control
into older pasteurizers which distinguishes
between recuperation and pasteurization
zones; to load new software to the
system or, if required, integrate new zone
divisions with additional spray tubes and
pumps, several control circuits, and new PLC
control and visualization.
The result: the dynamic PU control system
adapts as conditions change, enabling maximum
product safety and flavor stability.

competence 01.2013 44/45
Upgrades
in seven steps
Initiated by production …
The customer wants a solution
... or the technological experts
KHS Service makes an active
recommendation
After Sales Service quickly
draws up a solution
Intensive consideration of alternative
technical systems
A quote for parts and installation
is prepared
The ROI is individually calculated based
on a simulation program, animation,
and energy/water/CO₂ savings
The order is placed
The customer opts for the upgrade
and places an order
Format parts are manufactured
Format parts are manufactured
Initial test phase at KHS
Initial test phase at KHS
Integration of the new system
on the customer’s site
Integration of the new system
on the customer’s site

Service
The top ten: number 5
Shrink tunnel upgrade (I)
The situation: KHS shrink tunnels heated by
electricity consume a considerable amount of
energy.
The KHS offer: to convert these to eco shrink
tunnels by replacing heating cartridges with
gas heating cartridges and connecting the
shrink tunnel up to a gas supply.
The result: energy costs are cut by around
50% at a rough estimate, depending on the
prices for gas and electricity at the production
site; CO₂ emissions are also reduced by
up to 60%.
The top ten: number 6
Shrink tunnel upgrade (II)
The situation: energy is consumed in the
shrink tunnel even during machine standstill.
The KHS offer: to install a roller shutter system
and an electronically controlled standby
function for the shrink tunnel as an additional
option.
The result: on standstill the product infeed
and discharge openings close automatically;
at the same time the standby function re duces
the energy consumption of all functional units
involved in the shrink process to a minimum,
and on a restart they return to normal operation
within the space of a few minutes.
The top ten: number 7
Vacuum pump upgrade
The situation: the standard vacuum pump on
glass beer bottling lines needs fresh water for
cooling.
The KHS offer: to swap this for an ECO vacuum
pump with a heat exchanger. The compressed
gas passes from the vacuum pump to
the sealing water tank as a mixture of gas and
water; the compressed gas is then discharged
in the usual manner, with the water traveling
on to the heat exchanger where it is cooled.
The result: the ECO pump doesn’t need fresh
water for cooling, causing the water consumption
to drop by up to 96% compared to
the standard pump.
The top ten: number 8
Crown corker upgrade
The situation: older, mechanically controlled
beer fillers are difficult to access and difficult
to clean; the corking quality also begins to
decline.
The KHS offer: to install a new turret for the
crown corker, including crowning head support,
lubrication-free crowning elements,
the crown cork feed, sorter, flushoff facility,
torque dampers, and all the necessary electrical
components and format parts.
The result: easy cleaning, high biological
safety, minimized maintenance effort, longer
wear part service life, and shorter product
changeover times.
The top ten: number 9
Direct Flow Control keg upgrade
The situation: product loss through overfilling
and underfilling of kegs when using the
conventional gas counterpressure method.
The KHS offer: to retrofit Direct Flow Control
into the racking system, complete with a
DFC valve and the matching connections and
software.
The result: top filling accuracies at high filling
speeds; accurately controlling the volumetric
flow over the entire racking process saves up
to 10% product and up to 40% CO₂ during
keg pressurization; the product quality improves
thanks to low oxygen pickup.
The top ten: number 10
Flash pasteurizer upgrade
The situation: a relatively high consumption
of energy and superheated steam.
The KHS offer: new process technology, including
expansion or restructuring of the regenerative
section of the flash pasteurizer
plate heat exchanger; modification of the automation
system required for operation, including
all software and visualization.
The result: up to 70% of the heating and
cooling energy saved; around 60% less
super heated steam used and CO₂ emissions
reduced.
→ Contact
Shrink tunnels
are more energy
efficient with gas
heating cartridges.
Michael Beier | KHS GmbH, Dortmund, Germany
Phone: +49 231 569 1298
Email: michael.beier@khs.com
Armin Wille | KHS GmbH, Dortmund, Germany
Phone: +49 231 569 10284
Email: armin.wille@khs.com

46/47
Three questions for ...
… Günter Unkrig, head of After Sales & Service, KHS
How good is business? Are lots of beverage producers contacting you to bring their older systems
up to date with innovative technology?
Exactly. This happens in four out of five cases where we provide upgrades, or in other words update the lines and machines.
I should mention here that there are 40,000 KHS machines on the market at the moment, many of which are
incorporated into complete KHS lines. And about 40% of them have been working reliably for over 15 years, with many
of them in operation for 30 years or more – which speaks for the high quality and long service life of our equipment.
And what’s the remaining fifth of these plants doing?
Here we actively approach the customer. We suggest that they might like to use new technologies to bottle and pack
their products, giving them drastic reductions in both money and resources. This approach is part of how we see ourselves
as a customer-oriented company.
Could you give us a practical example?
Just recently upgrading a bottle washer with an output of 40,000 half-liter glass bottles per hour helped the
customer save around 1,600 tons of steam, 39,000 m 3 of fresh water, 143 tons of caustic, and 43 tons of additives a year.
That’s quite something, isn’t it?

Systems for sectors

competence 01.2013 48/49
The InnoPET BloFill monoblock consists of an InnoPET Blomax Series IV,
an Innofill NV, and an Innofill SV.
A big hit with
the public
For decades Lao Brewery has been going from strength to
strength, as two-figure growth rates illustrate /
This success is largely down to a policy of providing nothing
but quality, in which technology and consultancy from
KHS play a major part. In Laos the company is – and is sure
to remain – a big hit with the public.
In some countries the pace of life seems very different;
Laos or the Lao People’s Democratic Republic, to
give it its official title, is one of them. While the bordering
states of China, Vietnam, and Thailand are tainted by
the stress and bustle of an increasingly industrializing nation,
Laos radiates a peaceful air of composure. Tucked in
between its restless neighbors the country is like an oasis
where its unadulterated countryside, cultural wealth,
and Buddhist inheritance are treasured and upheld. The
price paid is that economic growth and prosperity are
slow in coming.
But stop! One company in Laos which has been going
from strength to strength at a rate of knots – while
maintaining its traditional values – is Lao Brewery. With
its Beerlao brand the company holds a 98% share of all
beer consumed in Laos, acting as a major economic factor
in this relatively small country with an output of over
two million hectoliters of beer per annum. Lao Brewery
sees itself as a “brewery for the country and its people”,
financing extensive social projects, supporting activities
to uphold the country’s culture and environment,
and selecting production technology with a sense of social
responsibility. The brewery was the first business in
Laos to call into being an environmental project that
aims to cut energy consumption and CO₂ emissions by
up to 40%.
For several decades KHS has been the partner of
choice to help achieve these goals, with Lao Brewery first
investing in technology from KHS in the early 1990s. The
first keg line was followed by four successive KHS turnkey
Triumphant advance
of water in PET
glass systems, the oldest of which has now been up and
running for 20 years. Kissana Vongsay, the managing director
of Lao Brewery, looks back with satisfaction. “Right
from the start we’ve had nothing but outstanding experience
both with KHS engineering and KHS’ services. For us,
KHS is simply a first-class company. On recently investing
in a new turnkey PET line for water there was absolutely
no question as to which trusted supplier would get the
commission: KHS, of course!”

Systems for sectors
The plus points
The turnkey PET line from KHS
1 STRETCH BLOW MOLDER
InnoPET Blomax Series IV
→→Space-saving design
→→Precise stretching
→→Low energy consumption
→→Fast and easy format changing
→→High process stability
→→Low maintenance, high machine availability
2 PET BOTTLE FILLER
Innofill NV
→→Exact filling volumes
→→Very short changeover times
→→High system availability
→→High flexibility
→→Maximum microbiological and hygienic safety
→→Low product loss
→→Resource-saving cleaning
3 ROLL-FED LABELING MACHINE
Innoket 360 S
→→Maximum flexibility
→→Fast format changeovers
→→Easy to adapt to individual requirements
→→Ergonomic design
→→Easy on resources
→→Maximum labeling precision
→→Tamper-evident unit included
5 PACKER
Innopack PPZ
→→High flexibility
→→Excellent accessibility
→→High system availability
→→Minimum maintenance effort
4 PACKAGING MACHINE
Innopack Kisters SP
→→Minimized film use
→→Fast format changeovers
→→High machine availability
→→User-friendly design
6 PALLETIZER
Innopal PBL1N1
→→Flexible changing of palletizing tasks
→→Fully automatic layer changeovers
→→High system availability
→→Minimum maintenance effort/number
of spare parts needed

competence 01.2013 50/51
“For us, KHS is simply
a first-class company.”
Kissana Vongsay,
Managing director Lao Brewery
The brewery has been bottling water since the year 2000.
With its Tigerhead brand, 60% of the Lao water market is
in the hands of Lao Brewery.
Despite its remarkable market share annual sales
presently only amount to 790,000 hectoliters (this was
just 76,000 hectoliters in 2005), as the market is still in its
infancy here.
The reason is that in a country like Laos bottled drinking
water is not taken for granted as it is in many industrial
western countries. Although tap water has to be boiled
before drinking for reasons of health and hygiene, and
bottled water is the only safe and readily available alternative,
most of the population simply cannot afford it. The
average income per capita here is about €820 a year – and
drinking water costs around €0.40 per liter.
The company has positioned Tigerhead on the market
as a premium water that meets international standards
of quality and safety and enjoys great trust as a product.
In order to profit from the growing demand with
Tigerhead, the new PET line was to primarily provide topclass
quality and exemplary hygienic conditions. Lao also
wanted to be able to output at a suitable capacity. The
brewery therefore invested in a KHS water line which can
process 45,000 0.6 and 0.35 and 20,000 1.5-liter bottles
per hour. The 0.6-liter size is especially popular on the market,
accounting for about 90% of total water sales.
The system:
many functions in one monoblock
In bottling water in PET especially KHS holds a leading position
the world over with its customized, cost-efficient
complete systems. Managing director Vongsay explains.
“Faced with such a strategically important investment
only KHS came into question, because we know from experience
that their technology is just as outstanding as
their consultancy and service. It couldn’t be better – and
we won’t settle for less.”
An InnoPET BloFill monoblock forms the heart of the
line, comprising an InnoPET Blomax Series IV stretch blow
molder, an Innofill NV filler, and an Innofill SV screw capper.
Monoblocking these three processing units gives the
brewery a maximum standard of hygiene. A minimum
number of interfaces and conveying segments ensures
a high degree of bottle material purity and prevents dirt
from entering the system. Another huge advantage is the
monoblock’s hygienic design. The support systems for
the function modules, for example, are made of painted
tubes, permanently welded to the machine. Aseptic membrane
and sealing technology is also a must in all productconducting
channels and passages and in the filling
valves.
Another plus on the hygiene front is that an airlock
separates the filling and packaging areas from one another.
And finally, the electronically controlled Innofill NV
normal pressure filling system with sixty filling stations
performs non-contact filling through a free-flow filling
valve, thus maintaining maximum microbiological and hygienic
safety. The filling process is concluded by the proven,
classic Innofill SV screw capper.

Systems for sectors
Brief portrait: Lao Brewery
COMPANY
Name: Lao Brewery Co., Ltd.
Established: 1973
Owners: 51% Carlsberg Asia Co. Ltd.,
49 % Lao People’s Democratic Republic
Company headquarters: Vientiane
Brands: Beerlao Classic, Beerlao Dark,
Beerlao Gold, Tigerhead
Production facilities: two in Vientiane,
one in Pakse
SALES
Beer: 1973 30,000 hl
1995 200,000 hl
2005 1,000,000 hl
2012 2,100,000 hl
Drinking
water: 790,000 hl
Non-alcoholic
soft drinks: 400,000 hl Market
shares
98% beer
70% soft drinks
60% water
There’s one more small but important feature. It’s not rare
for product counterfeiters to fill tap water into empty PET
bottles from brand suppliers and resell these at the usual
market price. In order to prevent this, the Innoket 360
installed at Lao Brewery features an integrated tamper-
Tamper-evident system
prevents counterfeiting
evident sleever. The system installed at the labeler discharge
to save space applies tamper-evident sleeves to the
bottle necks which are then shrunk by hot air directly on
the discharge belt in a tunnel area. The Tigerhead brand
is thus completely tamperproof.
Kissana Vongsay is full of praise. “For us the monoblock
concept is just perfect – from the low consumption
of energy and water through the high precision of the
bottle manufacture and filling to the top product quality.”
Vongsay is just as enthusiastic about the labeling quality
KHS produces with its Innoket 360. The label is more than
just an aesthetic addition; it’s the final polish that ensures
that the Tigerhead brand is attractively presented at the
point of sale.
With innovative KHS PET line technology Lao Brewery
is equipped for the bottling of up to one million hectoliters
of water a year. This volume could be reached by the
end of this year if the company’s estimated 30% growth
materializes. Says Vongsay, “Then we’ll have to make more
investments” – possibly also so that he can implement new
product ideas. The managing director has the final word.
“Our motto is ’Nothing’s impossible’,” Vongsay states.
“We think in as many different directions as possible, and
launch the products the people of Laos like.” As we said
at the beginning, Lao Brewery is a big hit with the public.
→ Contact
Gerhard Schmitt
KHS GmbH, Singapore
Phone: +65 656 093 13
Email: gerhard.schmitt@khs.com

competence 01.2013 52/53
Left — The Innofill NV provides many practical benefits.
Above — Applying the original sleeves.
Left — The Innopack PPZ bottle packer.

Systems for sectors
A team tackles
big chunks

competence 01.2013 54/55
An entire hotfill PET line at Kofola is reserved for the filling of chunky fruit
beverages / One of the most successful producers of non-alcoholic beverages
in Central and Eastern Europe knows very well that successfully turning an
idea into an innovation is a question of teamwork. This includes filling and
processing technology from KHS.
10 mm
Larger fruit pieces of up to 10 mm3 in size
also find their way into the bottle.
The goal couldn’t be more ambitious: the
Kofola Group aims to become number
two among the producers of non-alcoholic
beverages in Central Europe. In Slovakia this
has already happened, where the company
has a financial market share of 16%. In the
Czech Republic the group is currently in third
place and comes seventh in Poland. There’s still
quite a way to go, yet René Musila, Kofola’s
echnical director, is confident. “We want to
provide our customers with attractive, highquality
brand beverages which are charged
with emotion and thus very much part of the
daily lives of those who drink them.”
Just how this policy can be successfully
applied to the product is exemplified by the
Kofola Group’s most recent innovation: a fruit
juice containing chunks of aloe vera. With
it Kofola is entering a relatively new, fastgrowing
category of premium juice which
consumers associate with naturalness and an
intense taste sensation. What’s more, adding
chunks of fruit makes consumers feel they are
actually drinking fruit – but only when the
original consistency of the fruit pieces is retained.
The processing and filling technology
must therefore handle the sensitive fruit cells
extremely gently so as not to damage them.
KHS has developed a new technology for this
purpose which scores on all counts.
Score 1:
natural quality retained
Before starting work on the process engineering
KHS studied the fruit fibers and fruit
chunks contained in Kofola’s fruit beverages
at its own in-house laboratory. Based on this
analysis KHS developed a processing and filling
technique which retains the natural quality
of the sensitive solids on their way into the
bottle – even of larger solids of up to 10 mm 3
in size. KHS opted for a hotfill process in plastic
bottles which very specifically separates
the solids phase from the liquid phase.
Score 2: cost efficiency
The liquid phase is fairly conventional and
cost efficient; the sensitive fruit pieces – both
as a raw ingredient and during processing –
are a major cost factor, however. The KHS process
thus operates on a minimum/maximum
principle. It performs the more elaborate solids
phase with the lowest possible amount of
solid, largely retaining the shape and consistency
of the valuable ingredients by utilizing
gentle process technology.
Score 3:
gentle mechanical product treatment
Slow stirrers, pumps with a low backflow pressure,
and displacement pumps in place of rotary
piston pumps especially ensure minimum mechanical
stress during the solids phase. Smooth
conveying routes and the lack of narrow swing
bends and equipment – largely without control
valves – ensure particularly gentle transport
of the fruit pieces and fruit cells.

Systems for sectors
to just one type of product but can perfectly
process all kinds of fruit beverage imaginable –
from juices to smoothies.
“As employee and customer satisfaction go hand in hand
at our company, and partners like KHS support us in
every possible way, I’m sure that the Kofola Group has
outstanding chances for growth on its markets both
now and in the future.”
René Musila, technical director of Kofola
Score 4:
product thermally protected
Heat exchangers in the form of pipe heat exchangers
are used to pasteurize and cool the
product, ensuring even, homogeneous heating
and mixing. The pump has been designed
so that exactly the right amount of product
reaches the ring bowl of the filling system for
the solids at all times. Should the filler stop
briefly, it’s possible to run the product through
a bypass, cool it down, and then buffer it in
a rework tank. The advantage of this is that
the thermal process is not abruptly halted;
cooling also prevents too long a thermal load
on the product. If downtimes are longer, the
product is discharged to the rework tank and
the process engineering system rinsed with
hot water to sterilize it.
Score 5:
high energy efficiency
There is a permanent exchange of energy
between the three heat exchangers which
heat, pasteurize, and cool the product. This
environmentally-friendly recycling of waste
heat gives plant operators maximum energy
efficiency at a minimum cost and is thus also
sustainable.
Score 6:
automatic quality assurance
All quality-relevant parameters, such as product
temperature and flow rates at the infeed
and discharge are automatically measured
and recorded by the machine. Should these
parameters deviate beyond the given tolerances,
the bypass to the rework tank immediately
cuts in. This prevents any product not
properly processed from being fed to the
filler.
Score 7:
maximum flexibility
The non-alcoholic beverage market thrives on
a constant input of innovative products, flavors,
and containers. Consumers are erratic
and trends can quickly change. This is why the
KHS line developed for Kofola is not restricted
Score 8:
simple product changeovers
Changing the system over to a different product
is a very simple affair. The process technology
includes a recipe memory where the
exact parameters for the processing of each
individual product are stored for retrieval at
the push of a button.
Score 9:
automatic CIP cleaning
Automatic CIP cleaning of the process engineering
system by spray heads arranged at
staggered intervals reliably removes any remaining
fruit fibers and pieces. The only item
cleaned mechanically is the filter sieve integrated
into the screw conveyor. The cleaning
process for the solids phase and liquid phase
is otherwise identical; after a pre-rinse with
cold water, the equipment is cleaned with hot
water and caustic or acid before the final rinse
with sterile water.
Score 10:
gentle filling
The solids phase now prepared for filling is
fed to a piston filler with a low shear stress
for the product, ensuring that the fruit chunks
enter the bottle in perfect quality.
Score 11:
precise dosing
So that each filled PET bottle contains the
same amount of fruit pieces, these are filled
prior to the liquid phase. This means that the
percentage of solid can be precisely dosed.
The special solids phase treatment now ends.
The PET bottles freshly filled with fruit pieces
or fibers then undergo the hot liquid phase
for final filling; here, this is a conventional hotfill
process on a KHS Innofill NV-H. The Innofill
NV-H is suitable for the filling of fruit pieces
that measure up to 3 mm across, and of fruit

competence 01.2013 56/57
fibers up to 15 mm in length and 1.5 mm in
diameter. As at Kofola both filling systems are
monoblocked with one another, the company
enjoys further benefits.
Score 12:
microbiological safety
Monoblocking ensures a maximum standard
of hygiene. Aseptic membranes and sealing
systems are used throughout all product and
gas passages. And finally, non-contact filling
through a free-flow filling valve gives the beverage
plant maximum microbiological and
hygienic safety.
Score 13:
second optional flow
As Kofola’s monoblock system can process the
entire range of its fruit beverages, it’s of great
benefit to the company that the extremely
gentle but complex processing of fruit pieces
can be bypassed by a second product flow. If
this option is required, the products are both
prepared and filled by the process engineering
in the classic manner.
At the Mnichovo Hradiste site near
Prague in the Czech Republic, where the new
machinery is in operation, plant manager Karel
Teichmann is totally convinced. “KHS catered
for our needs at all times, developing a
system that was precisely tailored to our specifications.”
Technical director Musila adds,
“We’ve already had totally positive experience
with seven KHS lines; here, too, our cooperation
couldn’t have been better.” Which goes
to show that it’s all a question of teamwork.
→ Contact
Alois Monzel | KHS GmbH, Bad Kreuznach, Germany
Phone: +49 671 852 2376
Email: alois.monzel@khs.com
Libor Smutek | KHS Branch Office, Czech Republic,
KHS s.r.o., České Budějovice
Brief portrait:
Kofola Group
1993 Founded as SP Vrachos
1996 Merge with Santa Napoje
2002 Procurement of the rights to the Kofola
brand and change of company name to
Kofola a. s.
Seven production sites, of which
two are in the Czech Republic
one is in Slovakia
three are in Poland, and
one is in Russia
Employees: 2,000
Main brands:
Kofola Kofola Original Cola and other flavors
Rajec Classic mineral water and flavored
natural mineral water
Jupi Syrup beverage
Vinea Grape juice
Semtex Energy drink
Snipp Fruit juices and nectars
Jupik Fruit beverages, smoothies,
and near-water beverages
Pickwick Iced tea
Chito Tonic
Orangina Bottled under license
RC Cola Bottled under license
Phone: +42 38 551 5104
Email: libor.smutek@khs.com

Systems for sectors
Striding to the top
Production started just a year ago – and already they’re on their way
to becoming market leader / Khmer Brewery in Cambodia is growing
at a speed that’s hard to beat. At the helm of the company is an experienced
manager who has also trained as a master brewer.
KHS played a major role right from the very beginning.
The second top brewery on the national market in the
space of just half a year: this sounds incredible – but
it’s true! We’re talking about Khmer Brewery in the Cambodian
capital of Phnom Penh and its senior executive
vice-president Peter Leang. The story in brief: as manager
of the family-run Chip Mong Group, Leang gained experience
in the sale of imported beer. His keen sense of
business for new areas of activity and intensive market research
prompted him to launch a general offensive on the
beer market in his native country.
But first things first. About five years ago Leang began
carefully planning production. He first needed to choose
suitable technical equipment for his brewery – and went
for a canning, a glass, and a keg line from KHS. In doing
so he strictly adhered to the philosophy of the Chip Mong
Group which states that ultimately the best and most effective
solution is to always invest in excellent technology
right from the beginning.
There was thus no question when it came to the recent
procurement of a second turnkey canning line; the
exceptionally successful brewer again opted for KHS. The
line processes up to 60,000 0.33-liter cans per hour, thus
tripling the canning capacity from 30,000 to a total of
90,000 cans an hour.
Senior executive vice-president Peter Leang learned
the great art of making top-quality beer during his period
of training to become a master brewer. The Cambodian
manager wanted to know how you make excellent beer
right from the start. In 2010 he thus graduated as master
brewer from the Versuchs- und Lehranstalt für Brauerei or
VLB in Berlin; only then did Khmer’s MD begin to develop
CAMBODIA Beer with his team.
Only the best quality beer
Prior to doing so Leang compiled as much information as
possible and necessary on the Cambodian beer market
and its potential. He’d already decided on the name of his
beer brand: CAMBODIA Beer to symbolize the strong national
character of his brew. Says Leang, “We see ourselves
as the brewery for Cambodia which is why our brand beer
is fully geared to the national taste.” Khmer Brewery also
reacts to the high expectation the country has of its product
by committing itself to only producing the best quality
beer. However, it was a while before the right recipe
was found.
Leang’s team developed various possible mixtures
at their company headquarters in Phnom Penh and sent
them off to be brewed in Germany. The beers were produced
with the same top-quality ingredients Khmer uses

competence 01.2013 58/59
Spotlight: beer is in
Experts reckon on beer sales in Cambodia
rising by 15 to 20% every year.
In the next five years the current per
capita consumption of 18 liters
could therefore double. Here are the
main reasons:
+ The locals associate drinking beer with
a certain status.
+ With a growing per capita consumption
the sale of quality beers will undoubtedly
also increase.
+ Young people especially like beer. The average
age of the 14.5 million people in Cambodia
is 21.7 years (Germany: 44 years) Only about
4% of the population are older than 65.
+ Canned beer is particularly popular in the
Southeast Asian kingdom of Cambodia –
not least because it’s lighter to transport the
same amount of beer in cans than it is
in glass bottles.
Senior executive vice-president Peter Leang,
Khmer Brewery.

Systems for sectors
Khmer Brewery: view of the canning line.
Over
300,000
hectoliters
Mid 2012

competence 01.2013 60/61
1,300,000
hectoliters
in 2013 (planned)
750,000
HECTOLITERS
END OF 2012
Brief portrait:
Khmer Brewery
Khmer Brewery is a member of the Cambodian Chip Mong
Group. The family-run enterprise makes ready-mixed concrete
and also operates two trading companies for building materials
and fast-moving consumer goods. Khmer Brewery now employs
about 2,000 people.
November 2011: The brewery starts producing
CAMBODIA Beer.
Mid 2012: Beer sales amount to over 300,000 hectoliters,
making Khmer Brewery number two on
the market after just six months.
End of 2012: The total output is 750,000 hectoliters: 85%
in cans, 10% in kegs, and 5% in glass bottles.
2013: 1.3 million hectoliters of beer are planned.
By 2017: Turnover of four million hectoliters with further
investments. By this year Khmer aims to
be first among the breweries of Cambodia.

Systems for sectors
today. The fresh brew came back to Cambodia in kegs
where blind tasting sessions were staged for groups of
tasters formed according to the structure of the population
in the Southeast Asian country. There was a clear result;
the great majority voted for the recipe CAMBODIA
Beer is now based on. Brewery manager Leang describes
his beer as follows: “CAMBODIA Beer is a classic lager
containing 5% alcohol per volume. It basically tastes just
like a classic lager should yet has that certain extra for
Cambodia.”
CAMBODIA Beer has been on the market since November
2011 and is constantly breaking new sales records
(see Brief portrait: Khmer Brewery on page 61). This is
partly thanks to the fact that the brewery consciously acts
with a view to sustainability. The Chip Mong Group subsidiary
invested a total of €50 million in the building of
the brewery, with the environmentally-friendly waste water
treatment plant alone costing approximately €1.5 million.
Actions such as these are well received by the people
of Cambodia; not only the Cambodian prime minster was
present at the official opening ceremony but also 4,000
guests from the local area. At the event they were able
to examine the many ecological measures taken by the
company.
spray temperature. With it over-pasteurization is reduced
to a minimum and a high flavor stability secured even if
multiple stops occur.
The technology also allows Khmer to react flexibly
to new products and their treatment in the pasteurizer.
This point could soon be of interest to Peter Leang and
his team for at the moment they are thinking of launching
a second beer to the market adapted to the taste of
Cambodian beer drinkers. And last but not least, Leang
could also imagine expanding his business to embrace the
water and soft drinks sector. The Germany-trained master
brewer from the Cambodian metropolis is likely to keep
on striding to the top.
4,000 guests at the opening
Although Khmer Brewery exclusively focuses on meeting
the taste expectations of the Cambodians, the fast-growing
enterprise is also thinking of exporting CAMBODIA
Beer. On request the brew is already shipped to Japan and
Malaysia. At a later stage Khmer could also envisage not
only becoming established more strongly in Asia but also
in the USA and Europe with the aim of providing the many
fellow Cambodians living abroad and far from home with
their favorite, unique tasting beer.
Technically speaking, reaching out to countries far
afield is not a problem. The brewery’s pasteurizing technology
already in operation ensures a maximum product
shelf life. The KHS PU control always derives the optimum
→ Contact
Gerhard Schmitt
KHS GmbH, Singapore
Phone: +65 656 093 13
Email: gerhard.schmitt@khs.com

competence 01.2013 62/63
TOP — Can filler Innofill DMD
Bottom — The Innopack CA erects cardboard
box blanks, folds in the bottom flaps, and glues
them in place.
left — An Innopack PPZ packs the cans into
open boxes.
KHS technology: a second
powerful canning line
Khmer Brewery started production with three KHS turnkey lines:
a canning line, a glass line, and a keg system. The Cambodians’
love of beer in cans prompted the brewery to recently invest in a
second KHS turnkey canning line capable of processing 60,000
0.33-liter cans per hour. This brings the brewery’s canning capacity
up to 90,000 cans an hour. The chief details and benefits
of the new line:
The Innofill DVD can filler
+ 76 filling stations
+ Maximum filling accuracy through electromagnetic inductive
flow metering
+ Deviations in can sizes supplied by various manufacturers are
no longer a matter of concern
+ Aseptic membranes and sealing technology are used inside
the filling valves and in all other product-conducting channels
and passages
+ Minimum use of CO₂
+ Low oxygen pickup with positive effects on the shelf life and
flavor stability
Packing and palletizing technology
+ An Innopal AS1H depalletizes empty cans fully automatically
+ Cans are placed in boxes fully automatically by an Innopack
PPZ packer
+ Packs are palletized by an Innopal PBN1
The Innopas PISC pasteurizer
+ Safeguards the beer quality.

Systems for sectors
Cutting-edge technology:
the Innokeg Till Contikeg.

competence 01.2013 64/65
The keg king
Siberian Bochkari Brewery produces beer on Russia’s highest
performance keg system
/
Its success to date has prompted the brewery to invest in its seventh
keg line from KHS, as the sale of beer, kvass, and non-alcoholic beverages
in kegs is rising dramatically at Bochkari.
The exterior washing process is carried
out over several zones.
Even people who know Siberia well shrug
their shoulders when asked if they’re familiar
with Bochkari in the Altai Region. Ask a
connoisseur of excellent beers and you’ll get
a very different answer. Most of them can immediately
tell you that Bochkari is where the
brewery of the same name is located. The
company and its products not only enjoy an
outstanding reputation in Siberia but also
throughout the rest of Russia.
The history of the town goes back a long
way. Many generations ago Vadim Petrovich
Smagin’s forefathers, the Bochkarev dynasty,
were among the first to settle in Bochkari
and name the settlement after their family.
In a strange quirk of fate the word Bochka
can be translated into English as “barrel” or
“keg” – which is precisely the type of container
that has brought the brewery so much success.
In Siberia the keg is tradition both in the
hospitality and the beverage retail trade, the
latter being where consumers fill their beverage
into PET bottles fresh from the keg and
take it home. This practice is being increasingly
adopted in Russia, too; in the Russian capital
of Moscow beer shops have been all the
rage for the past five years or so.
The story of the company began in 1989
when Vadim Petrovich Smagin’s grandfather
opened the brewery. Six years later his grandson
joined what was then a small family business
at the age of 24. At the time everyone –
including the young Smagin – was ex pected
to literally lend a helping hand, with kegs being
racked manually, loaded by hand onto the
only company truck, and delivered to the various
points of sale. Yet it was all worth it.

Systems for sectors
“With our new Innokeg
Till Contikeg we’ve hit the
jackpot.”
Vadim Petrovich Smagin,
managing director of Bochkari Brewery
Within the first five years sales rose from
10,000 to 30,000 hectoliters a year. In the
middle of 2000 Smagin began to expand the
capacity. He says, “From this point forward we
were able to afford to only work with suppliers
of the best technical equipment.” This not
only marked the start of a partnership with
KHS but also of a positive sales boom “that we
couldn’t possibly have imagined.”
In 2012 Bochkari sold over one million
hectoliters of product (see Success in figures:
Bochkari Brewery on page 68). The turbulent
growth of the past few years is not only restricted
to beer; kvass, a carbonated soft drink,
and water are now also fixed features in the
brewery portfolio. Bochkari’s goal has always
been to provide variety in both its alcoholfree
beverages and its beers. In addition to
several brands of water, kvass, and soda, the
company also makes around 30 different
styles of beer. The Cheskoje, Zhigulevskoje,
and Andrejevic brands are particularly popular,
making up about 70% of the brewery’s
beer sales.
Brands increasingly popular
In the future kvass, mineral water, and other
soft drinks are to primarily boost sales. Managing
director Smagin expects that these
products will account for 45% of all sales in
2013 (in 2012 their share was just 40%). The
two water brands Aja and Serebrjany Klych
(silver spring) currently have sales bubbling,
with the result that quality and a broad spectrum
are not only boosting the popularity of
Bochkari products on the home market of Siberia.
The entire country of Russia is now familiar
with beer, kvass, and non-alcoholic beverages
from Bochkari with the number of fans
of the brewery rapidly increasingly.
In order to manage the expected growth,
Smagin and his personnel have decided to
notch up capacity in the kegging department.
Just recently another KHS line went into
production featuring the rotary Innokeg Till
Contikeg system. The new machine processes
an impressive 800 kegs per hour – and is
thus the highest performance keg system in
Russia. Bochkari’s manager explains. “The
main criteria for this investment were our
very good experience with our other KHS keg
systems, a functioning service concept, and
KHS engineers who were on site quickly – even
here in the south of Siberia.” Smagin’s first
account of the new setup is just as positive.
“The line has been running perfectly since
day one. We can therefore look forward to
a greater demand for our quality beer, kvass,
and soft drinks in kegs with total composure.”
KHS technology convincing
on all counts
Opting for the pioneering Innokeg Till Contikeg
rotary machine was not something the managing
director of Bochkari Brewery found
difficult. The benefits of the system had him
quickly convinced:
→→
Much less space is needed compared to
using several inline machines with the
same output

competence 01.2013 66/67
The perfect alternative:
disposable kegs
Bochkari products are selling better outside Siberia, too. However, long
distribution distances and lengthy return times make the utilization of classic
steel kegs largely uneconomical in this vast region. KHS thus presented
the brewery with the idea of the non-returnable Petainer keg (see KHS
competence 1/2012). At the moment two semiautomatic KHS Innokeg Till
PETBoy F2 Petainer keg racking systems are in operation at Bochkari.
Three questions for ...
… Rainer Deutschmann, director of Kegging Global Product
Account Management, KHS GmbH
What does the future look like for one-way kegs?
Very good. They’re revolutionizing cost management in the filling industry.
with more and more users of non-returnable containers around the globe.
What are the main cost advantages?
Compared to steel kegs these recyclable one-way kegs cut logistics costs by
between 20 and 30%, eliminate all expenditure for the return, storage, and
washing of empty kegs, and incur no changeover costs.
What’s the quality of the filled product like?
Disposable kegs from good manufacturers give you top product safety, this
ensured by state-of-the-art barrier technology. Shelf lives are at least nine
months. In short, the quality of the product is not inferior in any way to products
racked in steel kegs.

Systems for sectors
Six full kegs at a time
are palletized by a column
robot to form two layers.
Success in figures:
Bochkari Brewery
1989: Production starts in Bochkari
1995: 10,000 hl
2000: 30,000 hl
2011: 800,000 hl, of:
500,000 hl of beer,
200,000 hl of kvass and
100,000 hl of alcohol-free beverages
2012: 1,040,000 hl
2013: 1,200,000 hl (planned)

competence 01.2013 68/69
Keg turner: 800 kegs per hour.
→→
No longer any need to constantly cycle
the kegs from washing head to washing
head and then to the racking head.
→→
The technology is especially gentle on
the kegs and fittings
→→
Less piping and fewer valves, cables, and
wear parts are needed than on multiple
inline machines
→→
Fast installation, fewer servicing intervals,
and a reduced amount of control
air are required
→→
The system is permanently ready for
production and thus highly efficient;
it even keeps running even if a washing
or racking head is not functioning
properly.
After all, with the Direct Flow Control or DFC
filling process the Innokeg Till Contikeg at
Bochkari has another design feature that
boosts efficiency, giving them:
→→
Maximum filling accuracy
→→
Great pressurization gas savings
potential
→→
Extremely gentle product handling
→→
A permanently controlled racking speed
→→
Minimized oxygen and gas pickup in the
product
→→
Performance increased by up to 10%
compared to classic filling methods
→→
Exact fill level control.
“KHS technology and services play a major role
in the success story of our company,” praises
Smagin. He’s also convinced that his holistic
policy of quality has greatly contributed to
the brewery’s fast development. Bochkari is
therefore not just one of the most modern
food processing companies in Siberia; countless
awards also reward its firm determination
to produce and supply nothing but the best.
For example, Bochkari has won several gold
and silver medals at the Best Siberian Goods,
Russia’s 100 Best Goods, Best Siberian Beers,
and Best Goods in Altai competitions.
Says Smagin, “Everything we do has to
satisfy our very high quality targets. For only
then can our employees and with them the
people of Bochkari and the Altai Region feel
proud of us.” Together with his brewery, the
descendant of the first people to settle in the
small Siberian town thus acts with a great
sense of local social responsibility, at present
supporting the modernization of the school,
kindergarten, and hospital. The beverage
producer also sponsors various cultural and
sporting events in the region. And why does
he do this? “We’d like our personnel and the
people in our town and region to also profit
from the brewery’s enormous growth in
sales,” is the smiling reply.
→ Contact
Rainer Deutschmann | KHS GmbH,
Bad Kreuznach, Germany
Phone: +49 671 852 2977
Email: rainer.deutschmann@khs.com
Alexander Burenin | KHS Russia, Moscow, Russia
Phone: +7 495 7838100 1017
Email: alexander.burenin@khs.com
No other brewery on the
Russian market has such a
high kegging capacity as
Bochkari. The production
line includes:
1. Three KHS Innokeg Till
Transomat 3/1 inline
machines
2. Three KHS Innokeg Till
Transomat 5/1 inline
machines
3. One KHS Innokeg Till
Contikeg rotary machine
(the highest capacity keg
system in Russia).

Systems for sectors
The seventeenth Innokeg Till CombiKeg supplied
by KHS has gone to Brauerei Egger in Austria
/
Austria’s second largest private brewery been
steadily growing for many years.
The new keg line from KHS now paves
the way for more sales success.

competence 01.2013 70/71
17
IT HAD TO BE A
CombiKeg
The kegs are turned before they are
fed to the Innokeg Till CombiKeg.
left — View of the system: keg
infeed and discharge.
right — The KHS Innokeg Till
CombiKeg: compact enough to fit
into one shipping container.
Quality will prevail. This adage has lost
none of its validity as the successful story
of the privately-owned Brauerei Egger from
Austria illustrates. At the end of 2012 the
family firm was voted Lower Austria’s favorite
enterprise in the Austria’s Leading Companies
competition. The brewery’s positive image,
innovative drive, and creation of value
for the region were what convinced customers
and jurors.
Awards are nothing new to Egger; the
company from Unterradlberg near Vienna
has won both the International Golden America
Award for Quality and the Gold Medal
from the International Institute for Quality
Selections (Monde Selection). In the past
three years Egger Märzen beer has also been
presented with a gold medal by the German
Agricultural Society or DLG. Recognition like
this from the experts and consumers makes
Egger proud – and eager for more success. It’s
thus hardly surprising that the sales targets
of the multiple award-winner are very ambitious,
if not unrealistic. “In the not-too-distant
future we’re aiming to hit the million hectoliter
mark, and in the long term we could
see ourselves becoming Austria’s number
one private brewery,” reports master brewer
Wolfgang Reither. Egger’s “uncompromising
strategy of providing only quality” is to form
the basis of this dynamic growth.
Also a supplier of trade brands
This high standard of quality applies to the
entire product portfolio. About 80% of the
brewery’s sales are attributable to its awardwinning
Märzen beer which contains 5.2% alcohol
by volume and has an original gravity
of 11.8° Plato. The next bestsellers at 15% are
the lemon and apple Radler or shandies. The
remaining 5% of sales are shared by light beer
and hazy Zwickelbier.

Systems for sectors
Spotlight: Privatbrauerei
Egger
History
1978: The brewery moves from Tirol to
Unterradlberg near Vienna in Austria.
1988: The Egger company group starts
producing soft drinks.
The group also operates one of the
largest chipboard factories in Europe
with 17 production sites.
Sixty percent of the top-quality beer from
Unterradlberg reaches retailers in cans, with
35% bottled in glass, 2% in PET, and 3%
racked in kegs. However, the latter percentage
for kegs is soon to drastically increase. At
the moment the successful privately-owned
brewery is working full tilt to gain more customers
in the hospitality trade. Master brewer
Reither explains his strategy. “Our initial objective
is to expand locally close to our plant
and then travel further afield.”
Everything in one shipping container
In order to meet the planned increased demand
from restaurants and the like in the
near future – and with the maximum cost efficiency
– Austria’s second largest craft brewery
has invested in an Innokeg Till CombiKeg
R5 from KHS. This system, of which KHS has
now sold over 20, is an extremely compact
keg washer and racker format that fits into a
single shipping container. It can process up to
80 kegs per hour.
Wolfgang Reither discovered the many
benefits of the Innokeg Till CombiKeg during
a visit to the Schönbuch brewery in Böblingen,
Germany. He knew then that it had to be a
Beer sales in hl/year
750,000
600,000
450,000
300,000
150,000
1970s 1990s 2005 2012
1970s 50,000
1990s 300,000
2005 500,000
2012 700,000
Export share 20%
Exports go to Italy, Greece, Eastern Europe,
and Switzerland, among other places.
CombiKeg. What convinced the experienced
brewer first and foremost was that the new
system would satisfy Egger’s above-average
demand for quality.
Commissioning the CombiKeg line continues
the many years of partnership Egger
and KHS enjoy. For example, the brewery
has been using a KHS pasteurizer since 2008
which was incorporated into the KHS canning
line installed here at the end of the 1990s.
Prior to this the thriving company invested in
a KHS glass line. It thus goes without saying
that these two enterprises are keen to carry
on working closely with one another in the
future.
→ Contact
Edgar-George Petsche | KHS GmbH,
Dortmund, Germany
Phone: +49 231 569 1668
Email: edgar.petsche@khs.com
Katrin Goldhahn | KHS Austria GmbH,
Wiener Neudorf, Austria
Phone: +43 2236 62 510
Email: katrin.goldhahn@khs.com

competence 01.2013 72/73
7
PLUS POINTS
FOR EGGER
The successful privately-owned brewery in Austria only decided to acquire a KHS Innokeg
Till CombiKeg R5 after extensive market research. The seven points listed below were what
clinched the deal with KHS.
1 Lower costs. The keg infeed and discharge areas are
opposite one another which means lower investment
costs, shorter conveying segments, and less
space being taken up. The system can also be operated
by just one person.
2 Perfect washing. The system obtains excellent washing
results as all of the interior surfaces of the keg
exposed to product are covered with liquid process
medium.
3 Measurable sustainability. The Innokeg Till
CombiKeg uses water collected from the last hot
water spray to wash the keg exterior and flush
out any coarse soiling. This has a positive effect on
the brewery’s energy and water consumption.
4 Customized output. The compact new kegging system
operated by Brauerei Egger washes and racks up
to 80 kegs per hour.
5 Compact system. Media is supplied according to the
operating situation from caustic, acid, mixed water,
or hot water tanks integrated in the machine housing.
This also applies to the exterior keg washer. This
clever technical feature helps make the system as
compact as it is.
6 Maximum reliability. All interior washing processes
are continuously monitored by two components, i.e.
pressure and wet/dry signal probes. Should the pressure
of one of the media drop below a predefined
level, the machine is stopped. The machine also halts
if the probe indicates states that are not typical for
the process.
7 Efficient racking. The DFC filling system racks beer
quickly, gently, precisely, and economically – and
with a low oxygen pickup. What’s especially important
to Egger is the extremely low oxygen pickup
which largely contributes to securing the exceedingly
high quality of its kegged beer.

Special: sustainability
The future
in f cus
Quick check
How sustainable is
your company?
Page 77

competence 01.2013 74/75
A good image. A good conscience. A good yield. / Companies that
act sustainably boost their efficiency and their yield. Those that make
it a corporate philosophy earn customer loyalty, motivate employees,
actively take on responsibility, and protect the environment.
The consequence is that sustainability becomes part of daily business.
A look at sustainability in practice.
Sustainability. What is this exactly? In many companies
this term is used to describe a heightened sense of environmental
friendliness and social responsibility. Products go
green, offices are equipped with energy-saving lights, and the
toilets use water-saving flushing systems. Sponsoring a local
sports club or social organization is all part of the eco package.
And all of these activities are indeed worthy of praise.
“The notion of sustainability is
becoming more deeply embedded
in people’s minds.”
“But sustainability is much more that this and becoming increasingly
crucial to company survival,” says a man who knows
what he’s talking about. Stefan Schulz-Hermann, the initiator
of the German Sustainability Award, sees it like this: “Sustainability
is day-to-day business: real and arduous, something that
affects all processes and departments.” It’s no longer enough
to simply meet ecological standards. In our day and age acting
sustainably means taking on responsibility in the long term,
and encouraging the interplay of ecology, economy, and social
commitment throughout the entire company. And to do
this with conviction.
Our society has become more critical and no longer just relies
on what advertising says. “There’s a widespread attitude
today that calls for decent materials and ideal working and
production conditions in particular,” stresses Dagmar Fritz-
Kramer, managing director of wood manufacturer Baufritz
from Erkheim in Bavaria, Germany. Ulf D Posé, one of the
leading German ethics experts, has some positive news to report.
“The notion of sustainability is becoming more deeply
embedded in people’s minds. This goes for all stakeholders:
in other words customers, shareholders, the public, investors,
and employees.” Everyone wants to know just how seriously
a company takes the subject of sustainability before they put
their complete trust in it.
Fine chocolate makers create win/win
situation on the Amazon
Makers of fine chocolates Hachez from Bremen, for example,
illustrate what must be done to convince people. The company
not only concentrates on praising the unique quality of a
new type of natural chocolate made from wild cocoa beans;
Hachez also lets the public know that the gatherers of the superior
beans in the Amazon region are profiting from the new
chocolate highlight. Hasso G Nauck, managing director of the
company up to the start of 2013, provided his pickers with
modern cocoa processing equipment, and the company guarantees
certain purchase quantities. Says Nauck, “We’ve created
a win/win situation for ourselves.” Hachez is also committed
to the rain forest and can present consumers with a
product that is out of the ordinary.
However, those who harp on and on about how sustainable
their products are, are in danger of being accused

Special: sustainability
Case study: retailer
REWE Group listens
to consumers
Consumers are becoming increasingly interested
in where food comes from.
Initial situation: the increasing demand
of consumers for perfect quality, environmentally
friendly products, and reliable
information on the origin, production,
delivery conditions, and sale
of food.
The company focus: “Anyone who deals
with food has no other choice but sustainability,”
concludes REWE CEO Alain
Caparros. To this end the REWE Group
systematically involves all those in the
value chain to ensure sustainable production
and define common standards.
Proof:
→→The increasing utilization of electricity
from renewable sources is helping
to considerably cut down on CO₂
emissions. By 2008 over 6,000 of its
16,000 supermarkets were using alternative
forms of energy.
→→Reducing waste and recycling are
other major concerns. In 2010 the
company was presented with two
valuable awards for these activities:
the German Sustainability Award in
the Most Sustainable Campaign in
Germany category, and the special
Germany’s Recycled Paper Friendliest
Company prize.
→→Fair Trade products have indeed been
included in REWE’s range of products
since as early as 1993.
→→Germany’s second largest food retailer
opened up a completely new
avenue when at the turn of the
millen nium it became the first in the
industry to publish a full status
report on chemical plant protection
for REWE fruit and vegetables.
→→The company is also setting stan dards
in the field of energy efficiency. Buildings
are being converted and newly
erected using innovative technologies
and materials.
The management also promotes sustainability
within REWE itself with its
many organizational measures.
According to the convictions of the
BAUM* environment prize winner 2012
these include regular meetings of a sustainability
strategy circle, extensive sustainability
controlling, and detailed sustainability
reports.
* German Association of Environmental
Management e.V.
Dagmar Fritz-Kramer
Managing director of wood manufacturer Baufritz
“If the interplay between sustainability
and economic efficiency is credible, the profits
will take care of themselves.”

competence 01.2013 76/77
of greenwashing. The public now gets very angry with companies
who promote their eco friendliness without making
a substantial and sustainable contribution to the protection
of the environment to almost the same degree as companies
guilty of grave misconduct. These include companies who
have to face accusations of tolerating the practice of child labor
among their suppliers.
Sustainability good for image and sales
Things look very different for Hipp, for example (see Case
study on page 79). According to consumers the famous
maker of baby food should be heralded as Germany’s most
sustainable company (despite the negative headlines concerning
one of Hipp’s products last year). This is the result of
the Sustainability Image Score or SIS drawn up by the Serviceplan
Group for the second time in the summer of 2012. The
study shows what kind of impact sustainable actions can have
on a company’s image, and on consumer acceptance and customer
loyalty.
Accordingly, sustainability is not only good for a corporate
image and sales; taking on responsibility in social areas
and treating employees with respect are increasingly important
factors for long-term company success. For instance, the
portfolio of sustainable activities undertaken by Baufritz has
long included commitment to local issues and support for
aid projects in distant countries. Another is that employees
at the company site benefit from a daycare center and pioneering
working time models. Whether such measures really
pay off or whether they are just false investments is measurable,
says Dagmar Fritz-Kramer. “New fields of measurement
have to be defined to be able to assess soft factors like these.
This could be how the illness rate among employees develops,
for example.”
More and more companies are now understanding that
the correlation between ecological efficiency and actively taking
on responsibility helps to cut costs and limit risks. Multiple
award-winning company manager Fritz-Kramer has a simple
formula. “If the interplay between sustainability and economic
efficiency is credible, the profits will take care of themselves.”
Jochen von Plüskow
Quick check: how sustainable is your company?
Part I: approach
and focus
How does your company deal with sustainability? The Center for Sustainable Company Management or ZNU at the University of Witten/
Herdecke, Germany, has drafted a two-part quiz for readers of KHS competence:
1. Mission statement
Does your company mission
statement focus on
sustainability?
YES NO
2. Targets
Is your company mission statement
geared towards sustainability
by indicators and measurable
targets (for example, x%
less energy to be consumed in
the following year)?
YES NO
3. Interaction
Are the three pillars of sustainability
accounted for when
making company decisions, i.e.
economy, ecology, and social
commitment?
YES NO
4. Diagnostics
Does your company compile
data on the three areas of sustainability
(such as sick leave)?
YES NO
5. Prognosis
Is there any prognosis on your
level of sustainability (for example
the ecological implications
of your products)?
YES NO
6. Conflict management
Does the management deal
with inconsistencies within
the company openly and
reflectively?
YES NO
7. Communication
Could you describe communication
as being open?
YES NO
8. Participation
Are important decisions in the
company made largely with a
consensus, even if somebody
has the last word?
YES NO
9. Capacity
Is there enough personnel and
financial capacity to implement
your sustainability targets?
YES NO
10. The learning curve
Does your company have an
open policy of error management
which is used to improve
processes and products?
YES NO
You will find the answers
on page 78.

Special: sustainability
Quick check: how sustainable is your company?
Part II: concrete measures
The second part of our quick sustainability check tests which efforts are being made in the three sustainable areas of economy, ecology,
and social commitment for nine different topics. This is based on internationally recognized principles, rules, and standards:
1. Climate/energy
Does your company check
its carbon footprint (for the
company itself and/or its
products)?
YES NO
2. Resources
Does your company practice
resource efficiency (for example
saving water)?
YES NO
4. Quality
Besides the usual quality standards,
do decision-makers and
employees also take sustainable
criteria into account such as
the recyclability of products?
YES NO
5. Fair value creation
Is a fair creation of value
along the production chain
important?
YES NO
6. Equal opportunities
Do disadvantaged groups
have a suitable development
potential?
YES NO
7. Health
Does the company support the
health of its personnel with
special programs (such as back
training)?
YES NO
8. Formation
Are there further training
programs for employees
that go beyond the legal
requirements?
YES NO
9. Demography
Does a personnel management
program exist to commit
existing and recruit future
employees?
YES NO
3. Biodiversity
Is your company committed to
preserving biological diversity?
YES NO
You will find the answers below.
Quick check: the answers
Please don’t count how often you’ve checkmarked yes or no. What’s important – and decisive – is
how you reflect on your answers. However, you should check your nos to see if there is room for further
action within your company. If you’ve ticked no for all or nearly all questions, maybe your company
doesn’t need to think about sustainability issues. But maybe things could change here. If most of
your answers are a yes, then congratulations! You’re working in a model company that practices a sustainable
economy.
The ZNU can carry out a much more detailed and in-depth sustainability check in your company, evaluate
the results, draw up an action plan, and also hold workshops on site if required.

competence 01.2013 78/79
Prof. Dr. Claus Hipp
Managing director of Hipp GmbH
“Consumers are willing to pay
more for safety.”
Case study: food manufacturer
Hipp screens ingredients
No other European manufacturer of
baby food is as popular with mothers as
the family-owned Hipp company from
Pfaffenhofen in Bavaria, Germany – despite
its higher prices. Managing director
Claus Hipp knows very well why his
concern has such a good image. “Consumers
are willing to pay more money
for safety, control, and organic farming,”
he states. Each year Hipp produces
about 64,000 metric tons of its
top-quality products – with a tendency
towards more. This ongoing success is
based on a sustainability strategy that
has been consistently applied for decades.
Proof:
→→The choice of raw ingredients plays
a major role. Hipp’s own organic seal
enables it to check that all suppliers
and products meet its high in-house
requirements.
→→The use of regenerative solar, hydro,
and biomass energy contributes
to the protection of the climate and
environment.
→→The company is already leaving a
negative carbon footprint at its headquarters
in Pfaffenhofen.
→→Pioneering technologies are helping
to drastically reduce its consumption
of energy and water. Compared
to 1979 optimized water circuits save
around 70% of its annual water use,
for instance.
→→In 2011 a recycling and circulation
system enabled nearly all organic
waste to be either recycled, used as
animal fodder, or turned into energy
at biogas plants.
→→The energy consumption has noticeably
dropped.
→→As Claus Hipp is convinced that acting
sustainably can only work if all
those concerned are involved in the
strategy, in 1999 the boss drew up
an ethics charter for his company.
The baby food manufacturer is continually
developing this manifesto for
fair trade and respectful conduct towards
its business partners, suppliers,
customers, and employees.
When a children’s tea from Pfaffenhofen
hit the headlines about a year
ago, Hipp reacted immediately and
pulled the product from the market –
with no discussion or attempts to placate
customers. Its sole focus was on
the safety of its youngest consumers.
This unusual measure was probably just
one of the many reasons that Hipp was
voted one of the three most sustainable
companies in Germany in 2012.
The safety of its youngest consumers
is in clear focus at Hipp.
Read more:
Anke Fischer, CFO/CHRO of KHS,
on sustainability at KHS

Special: sustainability
KHS has been implementing a sustainability
strategy since 2008 which is being as well received
by KHS customers worldwide as by the people
who work at KHS.
Emphasis on
values
Which benefits KHS’ sustainability policy offers the
beverage, food, and non-food industries and which
visions KHS has for the future regarding this topic
are discussed in the following interview.
KHS competence: Ms. Fischer, why is acting sustainably so
important to KHS today?
Anke Fischer: The more important topics like resource-saving
production and social behavior become to the public, the
greater value they also hold for our customers and our employees.
At KHS we see it as our responsibility to practice environmental
friendliness and social commitment and are making
our specific contribution with the many measures we
implement both internally and externally, all of which successfully
correlate with one another.
KHS practices sustainability
on many different levels
Interview with Anke Fischer,
head of Finance, Human Resources,
and IT at KHS
Could you give us a few examples of the internal and
external sustainability measures you’ve just mentioned
which aim to increase eco friendliness?
Over the past few years we’ve optimized our system of inhouse
refuse management and now consciously separate our
waste. Heating systems have also been replaced, buildings insulated,
insulated glass windows mounted, air conditioning
systems with passive cooling installed, lighting systems replaced,
and much more. We only use eco-friendly, recyclable
materials as packaging. Where possible packaging materials
from suppliers are reused, or in some cases sent back to
our suppliers for reuse or recycling. All told, the clear objective
is to permanently monitor our level of eco friendliness and
to continue to optimize it. It’s for this reason that we’re also
part of the ECOPROFIT program (ECOlogical PROject For Integrated
environmental Technology). KHS Corpoplast took on
a pioneering role in the KHS Group when it joined the project
back in 2004. This has definitely paid off. For example, the
amount of water used at KHS Corpoplast has since dropped
by 50% and its gas consumption by 70%. Our production site
in Dortmund joined ECOPROFIT in 2012. Our factory in Bad
Kreuznach was given its ECOPROFIT certificate for the first
time in February 2013. In the future we plan for other KHS
sites to participate in this project.

competence 01.2013 80/81
Anke Fischer
Member of the KHS Executive
Management Board
CFO, CHRO, and IT
“In our day and age no
company can afford
to neglect the aspect of
sustainability in its
corporate strategy.”
Have you noticed an increased interest from KHS customers
in certification which honors the aspect of sustainability?
Definitely. Our global customers especially are extremely interested
in this and explicitly ask about it. They very often treat
the practice of sustainability within their entire supplier chain
and their company as a composite part of their brand policy,
and thus attach great importance to confirmation from a neutral
body. KHS can provide plenty of evidence of this. In 1995
the company was certified according to ISO 9001 (a quality
management standard). As a specialist company KHS has also
been recognized according to the Water Management Act
since 1996. In 2010 we were certified in keeping with OHSAS
18001 (the Occupational Health and Safety Assessment Series).
We started carrying out ethical audits at the request of customers
in 2012. To date the production plants in Dortmund, Bad
Kreuznach, Kleve, Worms, Hamburg, and Ahmedabad, India,
have received certification. Ethical audits are also planned for
our factories in the USA, Brazil, Mexico, and China. For 2013
we’re planning on gaining our ISO 14001 environmental management
system and ISO 50001 energy management system
certificates. By the way, our plant engineering has recently been
certified as being energy efficient for the second time running
by TÜV SÜD, an independent certification authority that also
enjoys the highest international recognition.
Has KHS made it a strategic goal to take on a leading position
in its field when it comes to sustainability?
Our vision is for technological and service leadership which
naturally includes the issue of sustainability. The role of technological
leader can only be filled by the company who introduces
innovations to the market that are particularly efficient
and therefore both ecological and economical. KHS has based
its environmental guidelines on this and defined the protection
of the environment and sustainability in the handling of
natural resources as one of its chief corporate objectives. As
far as the social components of sustainability are concerned,
we’ll only be able to keep the best personnel if we challenge
them, support them, and provide them with an environment
they like to work in as a company they can be proud of.
Does each and every new development at KHS meet your
high demands with regard to ecological friendliness?
It certainly does! Prior to any development we test and optimize
both the manufacture of our technical systems, including

Special: sustainability
Anke Fischer
“We’ll only be able to keep
the best personnel if we
challenge them, support
them, and provide them
with an environment they
like to work in.”
the materials used, and also the consumables utilized by the
customer. A very efficient use of media is also crucial here.
Do you see sustainability as being particularly challenging
for an international company like KHS?
Our high demand for sustainability applies to all of our sites
worldwide. We therefore also enforce our standards of sustainability
and auditing worldwide. This isn’t always easy, of
course, as local actions must always be adapted to suit the legal
stipulations, traditions, social values, economic and technical
standards, et cetera, pertinent to the site.
Let’s take a closer look at the social components of sustainability
as practiced by KHS. What role do the ethical audits
you’ve talked about play, for instance?
As a rule, more and more attention is being paid to accepting
companies as business partners who find a life guided by values
important, so as to avoid any damage to their image right
from the start. Our ethical audits – among other measures –
demonstrate that social values hold a very special significance
for KHS. During these audits an external auditor carefully examines
the working conditions, level of occupational safety,
and the environmental friendliness of production in particular
at our plants. For this purpose the sites are visited and interviews with
individuals, groups of employees, and the human resources departments
carried out. Certification gives our customers neutral proof that
with KHS they’re dealing with a company that fully adheres to a correct
code of ethical conduct. Results of the KHS ethical audit can be viewed
on the Sedex database.
Have you been able to profit from the ethical audit internally, too?
Yes, we have. We’ve had confirmation that we’re an employee-friendly
company and are on the right track. And also because of this confirmation
we’d like to continue in this direction in the future. All told, KHS
was portrayed in employee interviews as being an attractive employer
who is concerned for the wellbeing of each and every individual.
Which paths do you mean, and what’s KHS doing specifically to be
classed an attractive employer?
For a start, we find the work/life balance of our personnel very important.
We offer courses on this, for example, as part of our program of
further training called Campus. We’re also mindful of targeted health
care and have set up a company health management system. At the
end of last year health action days were staged at our German production
plants for the first time which were very well received. So that employees
can take some exercise during their working day we recently

competence 01.2013 82/83
included what we call the active mini-break in our program.
In Dortmund we’re part of the Family-conscious Companies
in Dortmund project and are constantly learning more about
this. We’ve first initiated all of these measures in Germany. The
concepts that prove successful will of course be gradually applied
to our subsidiaries outside Germany.
You’ve just mentioned the Family-conscious Companies in
Dortmund project. Does KHS see itself as a family-friendly
company, and what is it actually doing in this respect?
We show great understanding for our employees’ familyrelated
issues. We support them when their children are ill,
for example, or if their parents need care. All told, we see ourselves
as being one big KHS family who help each other out
whenever possible. Our employees’ satisfaction with this concept
is also shown by the very low fluctuation we have in personnel,
by the way. At the moment there’s chiefly a very strong
bond with the various sites; however, we’re working on also
boosting the sense of belonging to the whole KHS Group. One
means of doing so are the international meetings held at all
levels, where, for instance, all KHS plant managers, all KHS
controllers, engineers, and the Sales team meet once a year.
In the future we plan to promote the exchange of employees
between our individual sites much more strongly.
Are social activities always initiated by the German plants
and then practiced at other KHS sites worldwide if they
prove successful?
The initiative is often taken by Dortmund, quite simply because
Dortmund is the headquarters of KHS and many of the
central divisions are housed here. This doesn’t mean that this
is always the case, however. If ideas originate, are implemented,
and take hold at other KHS factories, then we’re just as
happy to adopt them for the entire group.
Practicing sustainability always also involves training
personnel for the future. What actions does KHS take here?
At the end of 2012 we included a further basic module in our
Fit4Future restructuring program entitled Personnel Development
and Internal Communication. Part of this is to develop
programs of further training that qualify employees for future
challenges. We’re also expanding our qualified, future-oriented
jobs, for our requirements will change. In order to secure top
staff for KHS even in times of demographic change we’re
working intensively with schools and universities both in Germany
and beyond, presenting ourselves as a training-friendly
enterprise, offering internships, and supporting people writing
bachelor and master theses.
How does the subject of sustainability look for the
future for KHS? Will acting sustainably increase in
importance in your view?
In my opinion more and more emphasis will be placed on
working with suppliers who operate their company sustainably,
in the food industry in particular. I can also see the demand
of employees for more sustainability continuing to rise.
In the future the employer who has a high level of social competence
and is eco friendly in its actions will earn points. At
KHS we’re prepared to keep on learning and to implement
the things we’ve learned fast. We believe that this is the only
procedure that in the end will safeguard the future of our
company.
Ms. Fischer, thank you very much for talking to us.
The interviewer was Friederike Arndt.
“Global customers especially attach great
importance to certification.”

In-house news
View of the production shop
at KHS Bad Kreuznach, Germany
Ethical audits at KHS
BONUS FOR THE CUSTOMER
The Coca-Cola Company does it. Britvic,
Carlsberg, Diageo, and PepsiCo do it
too. As do Kraft Foods, Nestlé, Unilever, and
Procter & Gamble. Like these global players
in the beverage and food industries companies
all over the world are now using the Sedex
database. where they can check whether
and how the makers of the machines and systems
they use adhere to international ethical
standards.
With its approximately 4,200 employees
and customers on all continents, KHS is now
one of the officially validated companies. In
the past few months KHS has been audited
according to SMETA or the Sedex Members
Ethical Trade Audit. This code meets
both the requirements of the ETI (Ethical
Trading Initiative) and the ILO (International
Labour Organization). The correct procedure
is as follows: an external, independent
auditor examines the working conditions,
level of occupational safety, and the environmental
friendliness of production in particular
at each KHS plant. These experts visit and
assess companies or carry out employee interview
with groups and individuals and the
human resources departments, among other
tasks. After a successful audit each KHS factory
is presented with a letter of conformity,
enabling KHS customers to rest assured that
their manufacturer KHS behaves correctly according
to an ethical code of conduct – as it
always has done, but now with an official seal
of quality. This code of conduct covers issues
such as humane working conditions and the
rejection of child labor, a transparent use of
resources, and constant monitoring of anticorruption
guidelines. In turn, this gives companies
who trust in KHS technology the added
bonus of boosting their own image and
being able to provide knowledgeable answers
to justified consumer queries.
Ethical audits apply to each KHS plant
individually, i.e. to those in Germany, and to
those in the USA, Brazil, Mexico, India, and
China. Those interested can view the results
of these audits in the Sedex database. As the
next step KHS is planning on gaining its ISO
14001 environmental management system
and ISO 50001 energy management system
certificates. KHS is always one step ahead.

competence 01.2013 84/85
KHS supports VDMA Sustainability Initiative
Blue Competence
As a member company of the VDMA (German
engineering federation) KHS supports
the Blue Competence Sustainability
Initiative. For KHS, sustainability has always
been an essential part of development and
production, combined with a high sense of
responsibility for the environment and subsequent
generations.
The following excerpt from its website
illustrates how Blue Competence sees itself:
“Sustainability is here understood to balance
and integrate economic, ecological and social
aims. It is thus about responsibility in a wider
sense, for instance for wealth, education
and security, nature and the economic consequences
of globalization, structural changes
or demographic trends. [...] Blue Competence
has defined credible and resilient sustainable
criteria and standards which must be met by
all those who join the initiative [...] Therefore,
Blue Competence ensures greater transparency,
makes it easier for people to know what
they are dealing with and provides certainty –
for all those who are looking for sustainable
solutions and products or companies that act
in a sustainable way.”
Many pioneering technologies from KHS
satisfy these principles and objectives, such as:
www.bluecompetence.net
→→
A new pressure filling system that saves
up to 40% in electrical drive power compared
to standard systems
→→
A gas-powered shrink tunnel that saves
up to 50% in energy and cuts CO₂ emissions
by up to 60% as opposed to one
heated by electricity
→→
A newly developed stretch blow molder
that saves up to 25% in energy compared
to the previous generation, and
optimizes the use of preform material
down to the last tenth of a gram thanks
to improved PET bottle thicknesses
→→
Cost-efficient (non-returnable) Petainer
kegs* that cut down on cleaning agents,
shipping, logistics, warehousing, and repair
costs compared to the classic steel
keg still widely used; they are also 100%
recyclable.
As a partner company in the Blue Competence
Initiative, KHS once again underlines
its expertise as a provider of sustainable,
environmentally-friendly, market-oriented,
technically guiding technologies.
* Petainer is a registered trademark of Petainer LidKöping AB.
Salzgitter AG’s Capital Markets Day
KHS in Focus
At the beginning of December 2012
Salzgitter AG, KHS’ parent company, issued
invitations to its first Capital Markets
Day. After a successful business year in 2012
KHS GmbH was at the focus of the event.
Twenty-two financial analysts from nearly
all of the major German and English institutes
who assess Salzgitter shares seized the
chance to gain their own impression of KHS’
course of business, strategy, Fit4Future program,
and medium-term perspectives. The
KHS Executive Management Board also presented
its most recent product innovations,
outstanding sales successes, production network,
production system, and the economic
perspectives the company has. There then followed
an intensive dialog between the analysts,
the KHS’ representatives, and Salzgitter
AG’s Investor Relations Department, who also
participated. The guests’ positive reaction underlined
the success of Salzgitter AG’s first
Capital Markets Day, and especially endorsed
KHS’ ongoing endeavors with its Fit4Future
program.

In-house news
KHS presents the new
Innofill Glass Micro
In pole position with KHS:
Prof. E.h. Dr.-Ing. Johann Grabenweger,
CSO of KHS GmbH, dressed in keeping
with the motto of KHS’ evening event.
Trade show review (I): Brau Beviale 2012
Top marks
The Mercedes SLS GT3 specially driven
in for the occasion underlined the motto
chosen for the KHS evening event at Brau
Beviale 2012 in record time: “In Pole Position
with KHS”. The Executive Management Board
and employees had spent the day welcoming
customers and guests from all over the world
(most of whom were from Central and Eastern
Europe) to their bright, open booth which
once again proved to be a prominent meeting
point at Brau Beviale 2012. Gains at the
show included countless new contacts and
many intensified partnerships. KHS exhibited
two innovations for their visitors to admire
and investigate: the Innoket Neo all-round
labeler for maximum flexibility, and the
Innofill Glass Micro filler specially designed
for medium-sized breweries and soft drink
producers.
Both new machines were obviously very
popular with their observers as the first orders
placed by enthusiastic companies still at
the KHS show booth demonstrated. Prof. Dr.
Ing. Matthias Niemeyer, CEO of KHS GmbH,
was very pleased. “We were again able to
welcome and inspire many top visitors and
decision-makers. The innovations we presented
were very positively received by our
expert clientèle.” All those who took part
were convinced that Brau Beviale 2012 was
an important milestone for KHS in the run-up
to drinktec 2013 where – we can tell you now
– there will be a veritable bevy of KHS innovations
on show!

competence 01.2013 86/87
Trade show review (II): Emballage 2012
ESTEEMED AWARD
The success story of the Innofill Glass platform
system, which recently launched
the next generation of KHS glass bottle fillers,
continues. At the Emballage 2012 trade
show in Paris, France, a jury of trade journalists
elected the innovative filler concept to
be included in the special Pack Innovation exhibition
area. With its computer-controlled,
DRS-ZMS pressure filling system and full
range of benefits the concept is ideal for
the beer and soft drink sector in particular, it
was said. These extras include an optimized
hygienic design, enhanced filling quality and
line availability, short cleaning times, and reduced
costs for maintenance, power, water,
and detergents.
Many breweries and soft drink bottlers
the world over are already using this innovative
concept. And just recently the wine, sparkling
wine, and spirits industry has also been
able to profit from the many added bonuses
of the Innofill Glass.
Prof. E.h. Dr. Ing. Johann Grabenweger in front
of the award-winning Innofill Glass platform.
Ruhr University in Bochum:
new project with KHS
THE JOINT REBAS
PROJECT
Together with the Chair of Production Systems
at the Ruhr University in Bochum,
Germany, KHS has launched a research project
that aims to cut costs and promote sustainability.
The working title is Resource-efficient
development and optimized operation of filling
lines in the beverage and food industry by
implementing innovative simulation software.
The R&D project is being sponsored by the federal
state and the EU, and is managed by the
North Rhine-Westphalian State Office for Nature,
the Environment, and Consumer Protection.
The C. & A. Veltins brewery, Warsteiner
brewery, and companies Phoenix Contact and
MPDV Mikrolab are also taking part in the joint
project, known as rebas, which is scheduled to
run until the middle of 2015. The project begins
with practical studies of the returnable
glass lines for beer at Veltins and Warsteiner,
with the aim of deriving the first heuristics
and algorithms. Smart operating points will
then be established on the lines and resourcesaving
control circuits generated.
The aim is to produce the perfect line layout
with the focus on saved resources, and an
automation requirement specification for efficient
operation. KHS’ many years of process
expertise will also be pooled in the project for
PET, cans, and kegs. This will help to reach the
rebas target, namely to develop a simulation
software for all kinds of different lines. It goes
without saying that in the long term the results
will be worked into KHS line concepts with a
plus in efficiency and a competitive advantage
for KHS customers, enabling them to consume
less energy, raw materials, supplies, and operating
materials with the same output.

In-house news
Vietnam: KHS promotes vocational training
ALL FOR
TOMORROW
KHS has become involved in setting up the
recently founded German Vietnamese
Technology Academy or GVTA. The academy
is a unique concept on Vietnam’s educational
landscape, acting as a cooperative platform
within a dual vocational training system for
qualified personnel which bundles the expertise
of KHS and other German companies that
cooperate directly with KHS. These include
Siemens, Phoenix Contact, Sick, Danfoss,
Endress + Hauser, and VideoJet.
The infrastructure for the GVTA has been
provided by the Ho Chi Minh City University
of Food Industry or HUFI. Consultants gpdm,
specialized in educational projects and project
management, have taken on the coordination
of the academy and developed a
German minister Philipp Rösler welcomes the project at the opening ceremony.
curriculum which is geared towards the technology
provided by the cooperative partners the worlds of Vietnamese business and poli-
training. Many high-ranking officials from
and based on German occupational and academic
educational standards. The aim of the as was Dr. Philipp Rösler, Germany’s federal
tics were present at the opening ceremony,
GVTA is to help two to four thousand students
a year gain a bachelor’s or master’s has been present on the Vietnamese market
minster of economics and technology. KHS
degree and to provide them with an outstanding
technical and theoretical course of ning lines used in the country, for
for 20 years, supplying around 70% of all can-
example.
Trade show review (III): China Brew China Beverage 2012
Asia is wowed
The big breakthrough came in its jubilee
year; the tenth China Brew China
Beverage (CBB), held in September of 2012,
finally confirmed that this trade show for
the brewing and beverage industries has
become a fixed feature of the Asia-Pacific
region. Incidentally, Munich International
Trade Fairs (drinktec) has a long-term cooperation
agreement with CBB. Over 51,000
visitors from 74 countries were wowed by
the newest developments and technological
trends in the international liquid food
industry at the New China International Exhibition
Center in Beijing. In six halls providing
70,000 m 2 of space, a new record for
CBB, about 700 exhibitors from 22 countries
put their innovations and exhibits
on display – a plus of 17% compared to the
previous show. All of the world’s leading
companies were there; KHS, for instance,
was represented among other machines by
its Innofill DPG-ZMS filler with 108 filling
stations, monoblocked with a 12-station
crown corker. This system fills beer into
both glass and PET bottles very gently and
with low oxygen pickup at a rate of 10,000
to 75,000, 0.1 and 3-liter bottles per hour.
The filling system has no external mechanical
controls, has aseptic sealing systems
in all product and gas passages, is simple
to operate and maintain, and enables fast
changeover coupled with maximum machine
efficiency. In short, the Innofill DPG-
ZMS filler is just what the market in the Far
East wants.

competence 01.2013 88/89
Distinguished: the KHS InnoPET Blomax Series IV
TÜV SÜD certificate
In developing the InnoPET Blomax Series
IV generation of stretch blow molders KHS
Corpoplast concentrated on low overall operating
costs and saving resources in the production
of premium PET bottles. This concept
has now been distinguished by the independent
TÜV SÜD test and certification authority,
with the InnoPET Blomax Series IV receiving
the energy-efficient plant engineering
certificate. This rating enjoys great acclaim
worldwide.
The results of the TÜV study showed
that compared to the previous system the Series
IV saves up to 30% of the blowing pressure
needed, up to 43% in electricity, and
up to 49% of its cooling capacity. The values
accrued by TÜV SÜD are thus much better
than those listed by KHS Corpoplast. The
reason for this is that heating the preforms
with near infrared radiation halves the heating
time, and a redesigned valve block considerably
lowers the amount of compressed
air needed.
Dr. Michael Bunk, the head auditor at
TÜV SÜD, is full of praise. “We’re very pleased
that internationally active companies like KHS
attach such great importance to sustainability
in general, and specifically to energy efficiency.
This not only improves competitiveness
but also demonstrates a strong sense of
responsibility towards the environment and
society.”
By the way, KHS has also been granted
the energy-efficient plant technology TÜV
SÜD certificate for its new Innofill Glass filler.
With this series KHS recently launched the
next generation of glass bottle fillers, which
has met with huge interest in practice.
KHS Corpoplast: new assembly shop
Investing
in the future
After around eight months of construction
the new assembly shop at KHS
Corpoplast in Hamburg, Germany, is finished
and production underway. The new building
(2,500 m 2 ) will bring the production space
utilized by the company chiefly specialized in
PET stretch blow molders up to approximately
21,000 m 2 , or the size of four soccer fields. In
the medium term the new Hall 3 is planned as
the first phase in a larger construction project,
with the shop to be extended at a later stage
to include a second assembly hall of the same
size and an office building. One reason for the
project is that by 2013 KHS Corpoplast aims to
double its capacities compared to 2011, coupled
with the creation of new jobs.
“As the KHS Group’s competence center
for PET technology we desperately need more
space,” explains managing director Thomas
Karell, “thanks to the fast-growing demand
worldwide for our newly developed InnoPET
Blomax Series IV stretch blow molders.” Another
reason for the new shop is that compared
to the previous generation the new
Blomax series reduces energy consumption,
saves on compressed air, and makes much
lighter preforms possible, among other assets.
“Customers like this,” says Karell. “They’re
investing in the future, too.”
Dr. Michael Bunk (right)
hands the certificate
to Dr. Ing. Thomas van Hamme,
KHS Corpoplast.
QR code: construction
of the new Hall 3
in fast motion.

In-house news
A day in the life of Ulrich T.
Ulrich Tessmann is deputy manager of Plant Commissioning for Labeling Technology at KHS.
No machine that hasn’t been tested down to the last detail and adapted to suit customer requirements
leaves the shop in Dortmund. This is what his normal working day looks like.
→
7.00 am
The team discusses the daily agenda. Which acceptance materials are expected, what are the delivery
dates like, which areas could prove difficult? This means that everybody is always up to date. The team
then turns its attention to the fully assembled machine.
→
11.30 am
Interim report on whether every detail is right, such as the electrics, electronics, and the loaded programs
for the control, drive, and safety units. Tessmann’s team displays great powers of detection in
unearthing any possible malfunctions in the electrical and mechanical sections of the machinery.
→
2.40 pm
The labeling machine is configured with the utmost accuracy. All format parts have to be functioning
for use in practice. To this end the customer has provided sample materials. “The moments of crowning
glory for us are the performance test and running the machine in continuous operation,” says Tessmann.
“Just as the customer wants.”

competence 01.2013 90/91
That’s
my job
The man for detail …
eah, sure,” shouts Ulrich Tessmann,
“Yand it sounds very metallic coming
from under the carousel, “of course this here
is also part of my job.” OK, we believe him.
However, the deputy manager of Plant Commissioning
for Labeling Technology at KHS
has actually flown halfway round the world
to quickly and expertly commission a new
Innoket 360 labeler for a customer – more
or less for just a couple of settings and a few
touch points.
Things are usually not
what you expect ...
And then the machine should run. Should.
Decorating a good 50,000 bottles per hour
with perfect labels. But now it’s quit working!
Just before the start, with the management
already on its way into the production
shop, the man from Dortmund finds a problem.
Nothing serious – the cleaning crew was
probably a bit over-zealous again – but something
has come loose despite the countless
checks. What can be done? In a split-second
decision Tessmann relieves himself of his jacket,
grabs a suitable tool, and half disappears
under the stainless steel machine. Less than
five minutes later the specialist slides back
out again. Somehow one of the wires had
indeed become loose. Smooth jacket down,
greet management, press start button (or let
it be pressed), run official test run, accept machine,
instruct employees (again) and give
them a few useful tips – and then he’s back
on his way home.
... and then you have to give
your all
Please don’t think that every day of Ulrich
Tessmann’s working life is like this. He’s usually
in Dortmund and starts at seven in the
morning – Central European Time. Fifty-oneyear-old
Tessmann has been doing the job
he wanted for ten years now. “Metaphorically
speaking, I breathe life into the labelers,”
grins the technology freak, who finds that
“the practice has always been more interesting
than the theory.” The challenges he deals
with are those presented by innovative components
or sensors – or at present the newly
developed Innoket Neo labeling machine.
He also appreciates “the independent way
of working at KHS which requires that everybody
here be a bit flexible. Certain schedules
could mean that I might have to work at
a weekend or dash round the world. The main
thing is that the customer’s satisfied.” Sure –
that’s his job!
Jürgen Jacobs

Click by click
KHS web news
INTERACTIVE PLANT
ENGINEERING
1. Interactive KHS website
Much of the information most often accessed
on the KHS website is on its plant engineering
for the beverage, food, and non-food industries.
Presented in a standardized layout, the
contents clearly list the main facts on the core
machine and the extra services that make
KHS the partner for reliable and durable system
solutions.
This has now all gone interactive and really
come alive! Thanks to graphic imaging the
user can now ’play around’ with the system
and get to know it in more detail. The single
machines as they appear on the line provide
the main body of information, with each machine
subject to in-depth scrutiny as required.
Interlinked systems, such as process technology,
conveying systems, and the line IT, form a
constant framework. The user can easily navigate
the equipment, quickly and comfortably
retrieving extra information as and when
needed. And of course all of this can be accessed
from your mobile device, whether tablet
PC or smartphone.
www.khs.com
2. Films on YouTube
In its last issue KHS competence told readers
that KHS technology and systems had gone
to the movies – namely to YouTube! Our You-
Tube films give users a true-to-life impression
of how KHS implements interesting line designs.
All films include brief, user-oriented
descriptions.
www.youtube.com/KHSGMBH

competence 01.2013 92/93
KHS competence
PUblisher
KHS GmbH, Dortmund, Germany
Editors
KHS: Matthias Damm, Manfred Rückstein; Friederike Arndt, Bonn;
jj-media, Cologne; protext, Cologne
Graphics
KD1 Designagentur, Cologne
CONTRIBUTIONS
Klaus Baumgartner, Michael Beier, Alexander Burenin, Ludwig Clüsserath,
Rainer Deutschmann, Katrin Goldhahn, Frank Haesendonckx,
Hans-Werner Holzer, Lutz Körtge, Alois Monzel, Thomas Niehr,
Edgar-George Petsche, Michael Rapp, Gerhard Schmitt, Libor Smutek,
Armin Wille, Paul-Uwe Winterhoff, Michael Zwilling
TRANSLATIONS
The German version of the magazine has been translated into English, French, and Spanish by
Fachübersetzungen CP MacKusick
Photos / illustrations
Timo Beylemans; Nicole Bock; Cornelis Gollhardt; Kaiserdom Specialitäten Brauerei;
KHS; Sylvia Niggeloh; PepsiCo; Frank Reinhold; Jakob Schneider;
shutterstock (Adisa, Steven Bostock, Iakov Kalinin, Fedor Selivanov, wavebreakmedia, Radoma);
Jörg Schwalfenberg; Oliver Tjaden
This information is non-binding. Only the technical specifications of our quotes are
determinative with regard to design and scope of delivery. Subject to design modifications.
INFORMATION FOR ORDERING
KHS Competence is published in English, German, French, Spanish, and Russian.
Those interested can order further copies of the magazine at www.khs.com.
Addresses
KHS GmbH
Juchostrasse 20
44143 Dortmund, Germany
Phone: +49 231 569 0
Fax: +49 231 569 1541
Planiger Strasse 139–147
55543 Bad Kreuznach, Germany
Phone: +49 671 852 0
Fax: +49 671 852 2411
Enzingerstrasse 139
67551 Worms, Germany
Phone: +49 6247 97 0
Fax: +49 6247 97 3300
Ruwoldtweg 14
22309 Hamburg, Germany
Phone: +49 40 63703 0
Fax: +49 40 63703 36150
Boschstrasse 1–3
47533 Kleve, Germany
Phone: +49 2821 503 0
Fax: +49 2821 503 503
Email: info@khs.com
KHS Corpoplast GmbH
Meiendorfer Strasse 203
22145 Hamburg, Germany
Phone: +49 40 67907 0
Fax: +49 40 67907 100
KHS Plasmax GmbH
Meiendorfer Strasse 203
22145 Hamburg, Germany
Phone: +49 40 67907 364
Fax: +49 40 67907 353
KHS UK Ltd.
Unit 6, Monkspath Business Park,
Highlands Road, Shirley, Solihull
West Midlands B90 4NY,
Great Britain
Phone: +44 121 713 6900
Fax: +44 121 713 6935
Email: info@khs.com
KHS USA, Inc.
880 Bahcall Court
Waukesha, WI 53186, USA
Phone: +1 262 797 7200
Fax: +1 262 797 0025
Email: mike.brancato@khs.com
5501 N. Washington Blvd.
Sarasota, FL 34243, USA
Phone: +1 941 359 4000
Fax: +1 941 359 4043
Email: john.turner@khs.com
KHS Pacific Pty. Ltd.
P.O. Box 378
1–3 Freight Road
Tullamarine, Vic. 3043, Australia
Phone: +61 393 35 1211
Fax: +61 393 35 1331
Email: info@khspacific.com.au
KHS Asia Pte. Ltd.
371 BEACH ROAD
#25-08 KEYPOINT
199597 Singapore
Phone: +65 6560 9313
Fax: +65 6560 9910
Email: info@khsasia.com
KHS Machinery Pvt. Ltd.
Near Hirapur Chowkadi,
Vatva - Mehmdabad Highway
382435 Ahmedabad
Gujarat, India
Phone: +91 79 66100000
Fax: +91 79 66100010
Email: khs@khsindia.com

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