drinkworld Technology + Marketing 2/2023

ZKZ 62006 

ISSN 1433-1594 Vol. 27 No. 2 June 2023 US $ 12 · € 12 

Cover: Beverage Promotion through Wood Carvings 

Upcycling Spent Grain and Yeast 

Keeping the Festival Beer Flowing 

Sensor Technology for Automated Filling

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Editorial 

Getting older, gracefully 

It’s no secret that the beverage 

industry targets consumers according 

to age groups. Probably more research 

dollars are invested into Generation Z 

than any other at the moment. This is 

because they are new and different to 

those before and less understood. 

Another fascinating age group is the 

older population, the baby boomers, 

now becoming silver agers. They, 

excuse me, we, are actually very easy 

to read and our needs are simple. 

Firstly there are a lot of us and we are 

staying around longer than before. 

This means this market is growing 

with some studies expecting around 2 

billion by 2050. This group has a big 

interest in staying healthy and mostly 

enjoys a disposable income to help 

it happen, especially in developed 

countries where independent living is 

more common. 

Manufacturers can look at this 

situation from two sides. Firstly, a lot 

more products are coming to market 

with active ingredients to address 

health and vitality issues, and secondly, 

on the practical side, package size 

and design is being revisited for those 

growing older and weaker, or with 

smaller appetites or family size. 

Anti-ageing beverages are very 

prolific and more of them are coming 

all the time. They are often made up 

of superfruits, lots of vitamins and 

minerals, various assorted botanical 

ingredients and with a dash of scientific 

research, all mixed together, lightly 

carbonated and then bottled in glass. 

Much of the sale may be the sizzle, 

but older people are notorious for not 

drinking enough, so there are certainly 

a lot of positive results. There is also 

a lot of variety, since combinations of 

the above are almost infinite and new 

ingredients are being trialled all the 

time. 

Transporting beverages is sometimes 

a big challenge for older people. This 

was leading to a growth in home 

delivery services even before Covid. 

Smaller bottles or cartons are practical 

for many reasons and it‘s good to see 

sensible coming back into fashion. 

Another trend which silver agers 

are embracing is the Home Brewing 

Ian D. Healey 

Editor-in-Chief 

concept. Of course, this is not restricted by 

age group and indeed recent figures from 

the German Federation of Brewers (DBB) 

show that the number of registered home 

brewers has tripled in the past eight years. 

That‘s good news for sure. 

As we said above, it is important for people 

of my age to drink enough fluids. Whether 

this comes as a functional drink with fruits 

and vitamins or a unique self-made brew of 

hops, malt and yeast, the water is the key 

to staying fit and healthy for longer. 

Cheers 

drinkworld Technology + Marketing · June 2023 3

12.09.22 15:54 

Contents 

hnology 

d food 

ZKZ 62006 



Upcycling Spent Grain and Yeastand 


Sensor Technology for Automated Filling 

Issue 2 · June 2023 

For more than 60 years, promotional items for beer and beverages have 

been produced in the "Atelier Zillich", an old four-storey farmhouse near 

Tutzing, Germany. These are barrel bottoms, clocks, coats of arms and tap 

plates. drinkworld talked with Peter Zillich, Craftsman and Collector about 

his life's work. 

Our cover story starts on page 6. 

Cover: Atelier Zillich 

Ingredients 

10 Premiumization of Water 

16 Case Study: Upcycling BSG Waste to 

Produce Value-Added By-Products 

Processing 

20 How one OEM is Engineering with Sustainability in 

Mind 

23 For Efficient Applications in the Lab: Scale Up 

Your Automation 

24 Supplying Beverages at Large Events 

About 39 million tons of brewer’s spent grain (BSG) 

is produced annually worldwide. That is the same as 

approximately 3 900 000 waste removal trucks which, 

end-to-end will wrap around Earth’s equator 6.8 times. 

BSG is the residual waste stream that remains after 

the brewing of beer. BSG is remarkably high in protein 

and fibre, has some residual energy, and is a healthy 

food intake for human, animal, and earth - if prepared 

correctly. See page 16 for the full story 

The Paulaner Brewery Group has been using underground 

ring-based piping since 2010 to supply its Oktoberfest 

tents with beer. This year the brewery installed a world 

premier: the first above-ground vacuum isolated piping 

for the central beer supply system. The entire system has 

a modular design that offers the following advantages: 

weather conditions have no negative impacts and 

installation/deinstallation times are significantly reduced. 

The full details are on page 24 

4

Contents 

Departments 

3 Editorial 

33 Fax 

42 Supplier's Guide 

Events 

41 Calendar of Events 

Marketing 

6 Wood Craftsmanship in Drinks Promotion 

Atelier Zillich: Museum now For Sale 

38 Nearing the finish line: Vetropack Starts up 

Furnaces in New Plant in Northern Italy 

GROW 

YOUR 

BUSINESS 

fairtrade 

agrofood 

food + bev tec 

process & packaging 

ingredients 

bakery & confectionery 

Packaging 

28 Sensor Technology for Automated Filling 

34 First 5-liter party keg made of CO 2 

reduced tinplate 

36 Markem-Imaje’s Brand New Coding Innovations 

Impress Industry at interpack 2023 

2023 

Iran 

Tehran 

Iraq 

Erbil 

16 - 19 

June 

19 - 21 

September 

30th edition 

www.iran-agrofood.com 

6th edition 

www.iraq-agrofood.com 

Ghana 

Accra 

21 - 23 

November 

7th edition 

www.agrofood-westafrica.com 

2024 

Nigeria 

Lagos 

28 - 30 

March 

9th edition 

www.agrofood-nigeria.com 

Ethiopia 

Addis Ababa 

06 - 08 

June 

6th edition 

www.agrofood-ethiopia.com 

Sensors installed in a filling installation often look 

inconspicuous. But they are indispensable for efficient 

processes. Dinkelacker uses sensor technology at nearly 

every station. The technical requirements are very high Only 

selected sensor solutions can rise to the challenge. This is 

why Dinkelacker relies on technology provided by a specific 

partner. This series is particularly well suited for applications 

in the beverage industry. Take a look at page 28 for the 

complete story 

Show contacts at fairtrade Messe GmbH & Co. KG 

Ethiopia, Ghana, Ivory Coast, Nigeria 

Ms Freyja Detjen Tel. +49-6221-4565-19 • f.detjen@fairtrade-messe.de 

Ms Nele Winter Tel. +49-6221-4565-31 • n.winter@fairtrade-messe.de 

Iran, Iraq 

Ms Clarissa Nusch Tel. +49-6221-4565-11 • c.nusch@fairtrade-messe.de 

www.fairtrade-messe.de 

drinkworld Technology + Marketing · June 2023 5

Cover Story 

Wood Craftsmanship in Drinks Promotion 

Atelier Zillich: Museum now For Sale 

For more than 60 years, promotional 

items for beer and beverages have been 

produced in the "Atelier Zillich", an old 

four-storey farmhouse in Monatshausen 

3 near Tutzing, Germany. These are 

barrel bottoms, clocks, coats of arms 

and tap plates. drinkworld talked with 

Peter Zillich, Craftsman and Collector 

about his life's work. 

It all began in the early 60s with a wood 

carving factory in Söcking. At that time 

there was a great demand for figures of 

saints, angels, cherubs and crosses. In 

Germany after the war, people wanted 

to renew what had been destroyed or 

decorate their rebuilt houses. - Initial 

experiments with plastic yielded 

6

Cover Story 

foamed cherubs. A gifted animal carver 

remembered his Westphalian brewing 

acquaintances and series production 

could begin. 

they had to equip their guest rooms - for 

example with decorative coats of arms 

or barrel bottoms. This quickly changed 

when German breweries began to export 

beer, especially Löwenbräu, which 

had a particularly capable importer in 

This resulted in an independent studio in 

Starnberg's rented premises. However, 

the prerequisite was still a wood-carved 

model, which initially had to be molded 

with caoutchouc, later with the much 

more suitable silicone to enable threedimensional 

copies. 

Soon they had to move to a 500-yearold 

farmhouse in Monatshausen, which 

initially offered plenty of space for 

production and magazines. Even today, 

models from that time wrapped in 

yellowed paper lie under a sloping roof. 

Cutting the glass mat, cleaning 

equipment, mixing gelcoat, laminating 

polyester, accelerator and hardener 

mixed by themselves are together a lot of 

preparatory work. Lamination of a slug, 

demolding, hardening, deburring and 

dedusting takes a day. 

Then there was the painting. The beige 

blank gradually turned into old lager 

oak, the slightly silvery "iron ring" was 

finished and at the climax the actual 

trademarks or advertising slogans were 

hand-painted. Each piece is unique. 

Peter Zillich calls this handicraft and 

thus justifies the term "atelier" or 

"studio". 

Peter Zillich took over the business in 

1969. In Germany many breweries had 

contractually bound restaurants, in return 

drinkworld Technology + Marketing · June 2023 

7

Cover Story 

the USA. Zillich graduated from the 

FU and worked several times on the 

French beverage market, seized the 

opportunity. "We were globalizing when 

the word didn't even exist." 

This photo portrait shows the legacy of 

a company that seems to be still alive 

yesterday. It also includes drawings, 

files, ancient brewery templates, correspondence, 

reference and address books, 

etc. - Atelier Zillich was a member of the 

Luxembourg Gambrinus Brotherhood. 

With a nostalgic wink, Zillich would 

like his "museum" to be sold in its 

entirety. Visits are possible at any time. 

Interested parties can contact atelierzillich@t-online.de 

by e-mail for more 

details or to make an appointment. 

Peter Zillich talked with Sabine Straka, 

Editor-at-large with Dr. Harnisch 

Publications. 

8

Cover Story 


9

Ingredients 

Premiumization of Water 

by DONNA BERRY 

More than one million bottles of water 

are sold every minute around the 

world and the industry shows no sign 

of slowing down, according to a 2023 

report by the United Nations University 

Institute for Water, Environment and 

Health. This equates to about US$270 

billion and 350 billion liters a year, and is 

expected to nearly double by 2030. 

Most bottled water is consumed at 

home by those who say that their tap 

water is unfit for consumption, blaming 

it on contamination, chlorination or off 

flavors. These purchases are a necessity. 

For others, bottled water is purchased 

as a convenience for on-the-go 

consumption. Many also find appeal in 

the promises brands make. 

One of those promises comes from 

PATH, which has a mission statement 

of “Forging the PATH to end single-use 

plastic bottles.” PATH is a refillable, 

recyclable bottled water in a sleek, 

durable aluminum bottle that comes in 

three varieties. PATH Still is filled with 

ultra-purified water through a sevenstep 

reverse-osmosis process and 

enhanced with electrolytes for a pHbalanced 

beverage. PATH Sparkling is 

delicately carbonated, offering a slight 

effervescence. PATH Alkaline includes 

specialty electrolytes with a final pH of 

9.5 or higher. To kick off summer 2023, 

the company launched a limited-edition 

summer bottle of PATH Still that is 

perfect for on-the-go summer activities. 

Promises, Promises 

Through savvy marketing and valueadded 

formulations, bottled water 

companies tout the health and wellness 

benefits of proper hydration. Adding 

flavor without any calories is a common 

tactic. Carbonation is another, with 

the two often offered together. Other 

approaches to premiumize water include 

adding caffeine, vitamins, minerals, 

protein, fiber or other functional 

micronutrients. 

A growing brand in this space is Bubly 

from PepsiCo. Introduced to the U.S. 

market in 2018 in eight flavors—apple, 

cherry, grapefruit, lemon, lime, orange, 

mango and strawberry—the brand has 

grown with new flavors and caffeinated 

formulations, as well as distribution in 

select global markets. 

The brand is as much about being a 

flavored sparkling water with no calories 

and free of artificial colors, flavors and 

sweeteners, as it is about being fun. 

Cans and bottles feature bright, bold 

packaging, and unique smiles for every 

flavor. Can tabs include a witty greeting, 

such as “Hey u,” “hiii” and “yo,” and 

personal messages, such as “I feel like I 

can be open around u,” “hold cans with 

me” and “love at first phssst.” 

The brand’s first-ever limited-edition 

flavor—bellini bliss bubbly—was 

introduced late last year. It speaks to 

the growing ready-to-drink mocktail 

trend and features the tropical flavors 

of peach, pineapple and mango. 

“Bubly sparkling water has always been 

committed to creating fun, refreshing 

and unique flavors that truly resonate 

with our consumers, so we’re incredibly 

excited to unveil bellini bliss as our firstever 

mocktail,” said Zach Harris, vice 

president-water portfolio at PepsiCo 

Beverages North America. “We’re all 

about getting folks to see the bubly side 

of life. And bellini bliss helps people do 

just that.” 

The brand also now has a line extension: 

bubly bounce. The sparkling water 

provides hydration with a little (35 

milligrams) caffeine. The new line is 

packaged in the signature bright colors 

of the bubly brand but also sports new 

effervescent and energetic graphics. 

It comes in five combination flavors: 

blood orange grapefruit, blueberry 

pomegranate, citrus cherry, mango 

passion fruit and triple berry. 

“Bubly sparkling water was created to 

bring more smiles into the sparkling 

water category, and new bubly bounce 

takes it to the next level with caffeine,” 

said Harris. “As more individuals seek 

out sparkling waters with added benefits, 

bubly bounce delivers all of the delicious 

flavor and hydration of the original, now 

with just a kick of caffeine.” 

Bubly bounce is one of many 

carbonated waters with added 

functionality. Another is Bubbl’r, 

a flavored energy water line from 

Klarbrunn, an independent distributor 

and manufacturer of Pepsi products. 

It is loaded with antioxidants from 

vitamins and caffeine from natural 

sources (guarana seed extract), and 

10

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11

Ingredients 

touted as being a healthy alternative 

to traditional energy drinks. 

The five-calorie-per-can waters contain 

a little bit of fruit juice, mainly for color, 

and are sweetened with erythritol and 

stevia extract. Some of the more exotic 

varieties are blood orange mango, 

cherry guava and pitaya berry. The 

brand’s most recent addition is Triple 

Berry Breez’r, which is made from a 

combination of blueberries, raspberries 

and blackberries. It was developed in 

response to research showing that berry 

flavors are some of the fastest-growing 

flavors in the sparkling water category. 

“More than ever, people are looking 

for healthier beverages with functional 

benefits,” said Tyler Hartmann, director 

of marketing and brand development for 

Bubbl’r. 

Not to be left out of the flavored sparkling 

water trend, Perrier Carbonated Mineral 

Water, a brand that started in 1863 

in Vergèze, South France, and is now 

enjoyed in more than 140 countries, has 

entered this space with a canned line 

that depicts its iconic green bottle. Now 

owned by Nestlé Waters, the premium 

mineral water line comes in lemon, 

lime, L'orange, peach, pineapple, pink 

grapefruit and strawberry flavors. 

To educate consumers about the line 

extension, the company is running 

a “Feel the Flavor” global marketing 

campaign through 2023. The campaign 

is running across digital, social, shopper 

and experiential channels. 

Talking Rain Beverage Company, the 

maker of Sparkling Ice beverages, has 

also stepped up its game with marketing. 

At the beginning of the year, the 

company launched the Flavorful Giving 

program, an initiative that celebrates 

the people, places and communities 

that inspire consumers to “Live in Full 

Flavor.” Throughout 2023, Sparkling Ice 

is partnering with a different charitable 

organization every month—each with its 

own unique flavor—focusing on a range 

of topics including youth development, 

veteran care, wellness, education and 

more. 

The company is also growing its Sparkling 

Ice +Caffeine lineup. Just in time for the 

summer season, watermelon lemonade 

joined black raspberry, blue raspberry, 

cherry vanilla, citrus twist, orange 

passion fruit and strawberry citrus. Each 

can of the zero-sugar beverage contains 

70 milligrams of caffeine and only five 

calories along with antioxidants and 

vitamin A. 

On the “Still” Side of 

Innovation 

While bubbles are an attractive feature 

to many adult consumers, some prefer 

still water. But they, too, want to be 

12

made to feel special by their water 

selection. 

Acqua Panna, an Italian brand of natural 

spring bottled water owned by Nestlé, 

has been making inroads outside of its 

borders. “The water is sourced from 

the sun-drenched hills of Tuscany with 

each drop of Acqua Panna naturally 

filtered by the earth and perfected by 

time on a 14-year journey to the spring, 

giving it a special mineral balance for 

the smoothest taste,” according to the 

company. The water was first bottled in 

1880, and was the first still water to be 

produced in plastic bottles within the 

boundaries of Italy. 

Acqua Panna is an alkaline water with a 

pH of 8.0 or higher at the time of bottling. 

This contributes to its smooth taste 

appreciated by chefs and sommeliers 

around the world. This adult-centric 

still water is best consumed between 

53°F/12°C and 64°F/18°C, without ice 

cubes or lemon. 

Wood Craftsmanship 

in Drinks Promotion 

Atelier Zillich: 

Museum now For Sale 


atelier-zillich@t-online.de 

13

Ingredients 

For adults who want to flavor their 

still waters, Twinings offers a premium 

flavor enhancer called Cold Infuse. 

Each infuser includes fruits and herbs, 

specially blended to brew in cold water. 

Varieties include blueberry apple, lemon 

ginger, mango passion fruit, peach 

passion fruit, strawberry lemon and 

watermelon mint. There’s also varieties 

with additional benefits, such as 

immune support raspberry hibiscus and 

probiotics pineapple coconut. 

Adults aren’t the only ones with their 

own premium bottled still water. After 

all, most children don’t like bubbles 

either. 

Hapi Water was developed by a dentist 

who saw the damage sugar was doing to 

kids’ teeth. The drink was created as a 

healthy alternative to fruity beverages 

many kids tend to drink. It has also 

become a go-to for adults who are drawn 

to the taste and healthy ingredients. 

With zero grams of sugar, a good source 

of vitamin C and zero calories in every 

shelf-stable pouch, Hapi Water comes in 

apple, grape, punch and strawberry kiwi 

flavors. 

For even younger consumers, Gerber 

Products Company, a part of Nestlé, 

offers organic fruit-infused water 

to provide toddlers with on-the-go 

hydration in natural flavors little ones 

will love. Made with real organic fruit 

puree without any added sugars, 

artificial sweeteners or artificial 

flavors. The waters come in spill-proof 

pouches with a resealable spout, 

as well as multi-serve shelf-stable 

bottles. 

for Gerber Organic Fruit Infused Water 

could help to improve your little one’s 

diet and keep them hydrated throughout 

the day.” 

Healthy beverage choices are important 

for growing toddlers, and nutrition 

experts recommend water, milk and no 

more than four ounces of fruit juice per 

day for children one to three years of 

age. The Gerber toddler beverages are 

94% water with a splash of organic fruit 

puree and natural flavors. 

The Author 

Donna Berry is a food and beverage industry 

consultant and editor with over 25 years experience 

in tracking trends and advancements in 

product development. 

“Beverage habits are an important part 

of the nutrition discussion between 

parents and their little ones. While 

we often think about what foods a 

child is fed, beverages contribute 27% 

of a toddler’s daily calorie intake,” 

said Erin Quann, head of medical 

affairs at Gerber/Nestlé Nutrition. 

“According to Nestlé’s latest Feeding 

Infants and Toddlers Study, more than 

20% of toddlers drink fruit-flavored 

drinks, which contribute calories and 

added sugar to their diet but very few 

nutrients. Swapping fruit flavored drinks 

14

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15

Ingredients 

Case Study: Upcycling BSG Waste to 

Produce Value-Added By-Products 

Valorising through disruptive technology that’s faster than the speed of sound to create 

new income streams for manufacturers 

Green Cell Technologies® (GCT®) and 

RWH Holdings® (RWH®) have worked 

with several global brewers over a period 

of 8 years to understand the challenges 

around what to do with their leftovers – 

Brewers Spent Grain (BSG) and Brewers 

Spent Yeast (BSY) – and the answer, as it 

would happen, is Disrupt it. 

Preamble 

About 39 million tons of brewer’s 

spent grain (BSG) is produced annually 

worldwide. That is the same as 

approximately 3 900 000 waste removal 

trucks which, end-to-end will wrap around 

Earth’s equator 6.8 times. BSG is the 

residual waste stream that remains after 

the brewing of beer. BSG is remarkably 

high in protein and fibre, has some residual 

energy, and is a healthy food intake for 

human, animal, and earth - if prepared 

correctly. 

Unfortunately, BSG usually spoils within 

a day due to its high water, sugar, and 

protein content. 

This brief period makes BSG difficult to 

transport, and process further into food or 

other human-grade products. Therefore, it 

is predominantly used in the feed sector 

as it is not readily available for human 

consumption, (Food Valley, 2022). 

Molecules found in the cellular structures 

of meat, fruit, vegetables, berries, nuts, 

grain, seeds etc. provide sustaining 

nutrition to achieve good health and 

wellbeing. Those molecules represent a 

comprehensive - across the spectrum - 

variety of all the macro and micronutrients 

necessary for human beings (including 

animals and earth) to flourish. 

However, current food and beverage 

processing methods damage many of 

these ‘molecules of interest’ and nullify 

their efficacy. With reduced nutrition in 

processing and a loss of fibre, there is only 

a sense of satiety but not much nutritional 

or health benefit. Existing processing 

methods cannot easily and effectively 

process skins, seeds, and grains (which 

contain significant nutritional or valuable 

properties), or radically reduce the fibre 

particle size to a level that will not upset 

16

Ingredients 

the organoleptic sensibilities of the 

consumer. 

Therefore, a conventional processor ends 

each day with not only a large pile of waste, 

which impacts the environment, but also 

an end-product that is sold to consumers 

with a vastly reduced nutritional profile as 

compared to what it could be. Ironically, 

the ‘waste’ represents the majority of the 

raw material molecules that are required 

for optimal nutrition. The ‘waste’ also 

represents most of the fibre, which if 

ingested, would aid other nutritional and 

health benefits. Instead, consumers are 

mostly left fibre deficient. 

Disrupting BSG 

Disruptor® technology was used in 

several trials, to deploy a non-chemical 

process (Dynamic Cellular Disruption® - 

DCD®) to open greater than 99% of all 

cell structures of the BSG ‘waste’ mass. 

Important to note that DCD and Disruptor 

technology can be applied to any organic 

and some inorganic materials. 

During the DCD process, other than pipe 

loss, which is the same volume irrespective 

of the production size, there is zero waste 

generated as the plant material can be 

used in its entirety. 

DCD also renders bio-available, all the 

molecules for the body to utilise, and 

ensures digestibility of the insoluble 

material(s). DCD does not manufacture 

molecules but instead, extracts what is 

available within the cell structure - more 

efficiently. This is from the source material 

and therefore, outcomes are wholly reliant 

on the source material itself. 

DCD also reduces the microbiological 

contaminants, yeasts and moulds found in 

source materials – product that is passed 

through the Disruptor will show improved 

microbiological cleanliness. 

In short, the DCD process and Disruptor 

technology increases available nutrition 

per serving and reduces particle size and 

waste, which has a positive impact in the 

consumer as well as the environment. The 

increased extraction of molecules signifies 

an increase in yield and nutrition, and with 

the utilisation of what would normally be 

considered waste, has a positive economic 

Roy Henderson - CEO 

impact on the processing value chain as 

well as environmental impact – circular 

economy. 

Conventional Vs DCD/Disruptor 

Technology Processing – BSG 

Conventional manufacturing of BSG 

typically involves drying and milling 

into a powder. Analysis of the powder 

will show that the particle size remains 

big which influences the taste of end 

products (comments of “cardboard” and 

“grittiness” are common). 

Conventional drying and milling methods 

do not guarantee any increase in yield 

or nutrition, digestibility, or microbial 

cleanliness. 

DCD and Disruptor extract processing 

allows for particles to be reduced to sub- 

100 micron, microbially clean, increased 

available nutrition and bio-available – all 

in one step. 

The resultant emulsion can be dried, then 

milled into a very fine powder, complete 

with health benefits ready for further use 

in manufacturing if required. 

This then opens possibilities of extended 

product lines and additional revenue 

generation for brewers. 

BSG Testing Methodology 

Demonstrating that DCD and Disruptor 

technology adds value to BSG 

Jan Vlok - Head of R&D 

manufacture, 200kg of BSG were 

processed. Material samples were taken 

for analysis pre and post DCD and sent for 

independent laboratory analysis. 

1. University of Stellenbosch – pre and post 

DCD amino acid profile measurement. 

2. SGS (SANAS accredited commercial 

lab) – pre and post DCD microbiological 

and heavy metal measurement. 

3. Hearshaw and Kinnes (H&K) for 

pre and post DCD pesticide residue 

measurement. 

Results 

Phyto-Chemistry: Amino Acids (protein) 

The report shows an average protein 

increase of 29%. This is clinically very 

significant if one considers that the 

barley or starch source used for beer 

manufacture before it became BSG, was 

subjected to substantial boiling to conduct 

extraction for the beer manufacturing 

process of which, much of the protein 

will have already been solubilised into 

the beer liquid. This is proven by the step 

that is required to minimise it to prevent 

cloudy beer. 

Microbiological 

The report found that there was a 

1600000-fold decrease (99.999% 

improvement) in total plate count 

from 16000000cfu/g to 10cfu/g 

between the pre-DCD and post-DCD 

samples. The DCD process also reduced 

yeasts and moulds to “not detected” 


17

Ingredients 

from 16800cfu/g and 28000cfu/g, 

respectively. 

Heavy metals 

The test measured for heavy metals 

typically examined for food and beverage 

production safety, those being mercury, 

cadmium, lead, and arsenic. All results 

are

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2023 

/ E-mail: info@lubriplate.de / Tel: +49 (0) 4262 79 95 23 

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and ISO 50001 

19

Processing 

How one OEM is Engineering with 

Sustainability in Mind 

SPX FLOW, a B2B process solutions 

provider, conserved 6,150,000 liters 

in water use across its global sites 

in 2022. For B2C customers, water 

conservation shows up in the solutions 

B2B companies design, manufacture, 

and service for their production sites. 

A few revolutionary water reduction 

breakthroughs from SPX FLOW include: 

APV Homogenizer Water Recycling 

System (HWRS) 

Imagine you’re at Niagara Falls watching 

millions of gallons of water plunge over 

the steep cliff. Out of curiosity, you 

start counting. 

One thousand one … one 

thousand two … one thousand 

… 

All told, that’s enough time for about 

2 million gallons to cascade over 

Horseshoe Falls, one of the three marine 

marvels that make up Niagara Falls. 

That’s also how much water this new 

homogenizer technology is helping B2C 

customers save each year. And that’s 

just the savings for one homogenizer 

over one year. 

Traditional homogenization requires 

the use of copious amounts of water. 

The more homogenizers that are in 

use, the more water is consumed and 

wasted. Now imagine a plug-and-play 

system that can fit or retrofit to any 

homogenizer and reduce water usage 

by up to 97% [2]. You read that right 

- a homogenizer that uses just 3% of 

its current water consumption to run 

the same processes it currently runs. 

Featuring a closed-loop water treatment 

system, SPX FLOW has engineered the 

HWRS to virtually eliminate all water 

use and be easily installed or retrofitted 

to both new and existing homogenizers 

by any manufacturer. 

How it works: Where normally a 

continual flow of water gets supplied to 

homogenizers to cool the transmission 

oil and lubricate the plungers, the HWRS 

recaptures that water, cleans and chills 

it, then returns it into the homogenizer. 

It’s a crucial technology that comes just 

in time as the cost of water rises, and 

supply shrinks, making sustainability 

increasingly important. 

APV/WCB D4 Double Seat 

Mixproof Food and Beverage 

Valves 

Another B2C design SPX FLOW 

engineers cultivated to help reach 

water goals is the D4 valve series that 

optimizes the flow of fluid through the 

valve manifold. The series consumes 

up to five times less cleaning fluid 

than most marketplace valves during 

clean-in-place (CIP). This improvement 

leads to less chemical and water use 

which limits the amount of waste-water 

treatment, and the related energy 

consumption needed for this additional 

process. 

20

One B2C U.S. beer producer experienced the impact 

of these valves firsthand. It needed help optimizing its 

processing lines by introducing a valve that could meet 

rigorous production demands, but also minimize the effects 

of water hammering. There was ease of maintenance and 

safety concerns while providing production efficiency to 

balance too. 

It was such a tall ask that a range of competitor valves were 

kept on-site to test over time, and all failed to meet every 

requirement. The D4 Series Double Seat Mixproof valve was 

offered up as a contender. 

QUALITY 

GUARDS. 

Processing 

Naturally 

protected with 

Nagardo ® 

glycolipids! 

What they saw: 

The mixproof valve design resisted the hydraulic shock 

created by pressure spikes and high flow velocities and 

created more freedom within the process, a benefit given 

long-term plans for process expansion. Competitor’s valves 

led to false and nuisance alarms due to the external switches 

and cabling that were susceptible to snags and natural 

vibrations during operation. The D4 valve’s protected 

design was found to reduce potential false alarms. Enhanced 

sanitary measures like the D4 leakage chamber eliminated 

buildup / blockage that can compromise the process fluid’s 

integrity. The leakage chamber flush option also kept the 

vent area clean. 

While this brewery is a case study example, the D4 series is 

used across other dairy, processed food and personal care 

applications with wins of their own. 

APV Pigging Technology (ARRS) 

Ambient dairy and plant-based products are becoming 

increasingly popular across fresh product categories and 

introduced in regions with select taste preferences. Keeping 

dairy and plant-based products at ambient temperature 

while also maintaining their long shelf-life qualities requires 

special processing throughout and before packing, leaving 

no room for post-contamination. Given the amount of 

time and attention given to a process like this, none of 

the product should be wasted during water flush after the 

production cycle is over. Every drop counts and adds to the 

top and bottom line of B2C businesses. 

Safety enabled by nature 

Innovative natural 

preservative with EU 

approval 

Excellent performance 

Patented technology 

developed in Germany 

First preservation technology 

for non alcoholic 

beverages entering the 

European market since 

40 years 

nagardo.com 


21

Processing 

With this technology, one B2C 

custom 

er, when calculating the benefits of the 

ARRS, found it recovered a million dollars’ 

worth of residual product by year end. 

How did they arrive at this number? The 

extreme product recovery by the ARRS. 

Once a production cycle is over, the 

process line is typically cleaned-in-place 

(CIP) and/or sterilized-in-place (SIP) using 

cleaning fluids. This process is imperative 

for products such as ambient products and 

yogurts or dessert creams and cosmetics 

because cross-contamination can lead to 

product recalls and harm B2C consumers. 

After CIP/SIP is complete, a rubber, tightfitting 

projectile, is forced through the 

process pipeline, that cleanly scrapes and 

recovers residual product to limit waste. It 

leaves less than 0.5% in the line and offers 

87% in product savings in the product 

pipes between valve manifolds [3]. 

After scraping, the pig is returned to 

the launch station by compressed air, 

maintaining aseptic conditions, and 

keeping the line clear for the next cycle. 

The new APV innovation also yields up to 

50% more uptime since the minimization 

of repeated clean-in-place cycles 

translates to a reduction of chemical and 

water usage by 60-70%. 

In Honor of April 22nd 

Earth Day is celebrated each April to 

acknowledge the role we all play in 

the health of our air, waterways, and 

communities. You may see companies, 

brands and nations release statements 

and pledge commitments to the Earth 

around this time of year. But what’s 

more important are the steps we take to 

address our planet’s pressing needs not 

just on Earth Day but every day. In food 

and beverage manufacturing, energy, 

emissions, water and waste are used daily. 

These are natural byproducts of feeding 

and building the world, but how we do 

so, can be curbed to benefit ecosystems 

everywhere. 

B2B Companies like SPX FLOW are 

committed to leading by example to 

make our world safer, healthier, and more 

sustainable by innovating how things 

are made, conserving residual product, 

and aligning with the green goals of B2C 

producers to support a sustainable value 

chain from beginning to end. 

[1] As referenced by the United States Environmental 

Protection Agency; https://www.epa.gov/ 

sustainability/lean-water-toolkit-chapter-2 

[2] Figures contingent on actual running conditions 

within a plant. 

[3] Figures are indicative and dependent on actual 

running conditions. 

SPX FLOW, a B2B Process Solutions 

Provider, Engineers Sustainable 

Technology for B2C Production How one 

OEM is Designing Technology to Help B2C 

Customers Reach Sustainability Goals 

SPX FLOW Prioritizes Water Savings 

Technology Design for Customers B2B 

Process Solutions Provider SPX FLOW 

Sustainably Innovates for Food and 

Beverage Producers Food and Beverage 

Producers Reach Sustainability Goals 

with Help of SPX FLOW B2B Technology 

On the eve of Earth Day, we’re reminded 

of our planet’s beauty and rarity of 

natural resources essential to daily life. 

Water is one of these precious natural 

resources. The manufacturing industry 

generally uses more than its fair share 

of freshwater withdrawals, as much as 

18.2 billion gallons per day [1]. Given 

these numbers, food and beverage 

manufacturers design with sustainability 

in mind, particularly attune to reducing 

water consumption. 

Business-to-business (B2B) manufacturers 

must prioritize sustainability 

goals to help business-to-consumer 

(B2C) companies reach theirs. This 

symbiotic relationship cultivates an 

internal supply chain of water, waste, 

emissions, and energy savings that not 

only helps save the planet but increases 

B2C companies’ bottom line. The less 

consumed in the process line, the less 

invested in replacing material further 

down the line, particularly in processes 

like clean-in-place between batch cycles 

22

Processing 

For Efficient Applications in the Lab: 

Scale Up Your Automation 

METTLER TOLEDO makes working with 

its UV/Vis spectrophotometers more 

effective: The "InMotion" autosampler 

independently and reliably feeds samples 

for analysis. In addition to the standardized 

25 to 100-milliliter sample volumes, 

customized sample racks developed for 

individual customer needs are unique. 

This advances laboratory automation, 

for which the company offers further 

instruments and sound advice. 

Unrivaled in individual sample 

racks 

With standard sample volumes of 25 

to 100 milliliters available in a modular 

system, the "InMotion" autosampler 

scores particularly well with extensive 

analysis material from the chemical and 

beverage industries. 

The UV/Vis spectrophotometer 

can be 

easily connected to 

the InMotion via an 

immersion probe or 

flow cell, making it 

an effective tool in a 

range of instruments 

the manufacturer 

has developed for 

efficient and safe 

automation of 

analytical processes. 

Start smart 

METTLER TOLEDO advises that 

spectrophotometric automation brings 

the most significant efficiency gains 

when customized. This is why the 

company focuses on information and 

advice right from the start. For the 

very first step towards automation, 

METTLER TOLEDO provides informative 

documentation in the form of a guide 

and webinar. 


23

Processing 

Tapping the first keg in the Bräurosl festival tent on opening day of the 187th Oktoberfest on the Theresienwiese in Munich, 9 September 2022. Image: 

Hannes Magerstaedt 

Supplying Beverages at Large Events 

World premier – first in-tent vacuum insulated piping (VIP) system for festival beer at the 

Munich Oktoberfest 2022 

In 2022, millions of visitors once again 

visited the Oktoberfest in Munich 

after a two-year hiatus forced by the 

corona pandemic. And none of them 

died of thirst! The Paulaner Brewery 

Group introduced a world premier 

this year in the Pschorr Bräurosl beer 

tent: the first vacuum insulated piping 

system (VIP) for beer installed directly 

in the tent at a height of 3.5 meters. 

The measurement technology for the 

smooth operation of the beverage 

The Picomag instruments from Endress+Hauser (nominal diameter DN 15) measure the flow, temperature 

and conductivity values of the non-alcoholic beverages. 

Image: Endress+Hauser 

supply system, including the nonalcoholic 

keg dispensers, is from 

Endress+Hauser. 

Paulaner has been using underground 

ring-based piping since 2010 to supply 

its Oktoberfest tents with beer. This year 

the brewery installed a world premier 

in the Bräurosl tent: the first aboveground 

vacuum isolated piping for the 

central beer supply system. The entire 

system has a modular design that offers 

the following advantages: weather 

conditions have no negative impacts 

and installation/deinstallation times are 

significantly reduced. The temperature 

difference is a mere +0.3° C within 24 

hours, at an ambient temperature of 30° 

C and a beer temperature of 0° C. This 

represents a considerable improvement 

over the underground piping system. 

Another centerpiece is the measurement 

technology from Endress+Hauser. As 

summed up by brewing engineer Uwe 

Daebel: “Our recipe for success: we 

have the innovative ideas and work 

24

Processing 

together with reliable partners like 

Endress+Hauser to implement them.” 

The measurement technology can 

be found at many points within the 

Oktoberfest tent: 

Bierant for the Oktoberfest 

beer in the tent* 

(*Works according to the artesian 

principle. Any air or gas present in the 

VIP system is removed and the beer is 

distributed to the taps via “pythons”). 

An ingenious idea by Uwe Daebel, 

brewing engineer at the Paulaner 

Brewing Group! Everyone knows what 

the word hydrant means and how it 

functions. According to Wikipedia, a 

hydrant is an outlet from which water 

can be tapped. Accordingly, a socalled 

Bierant © (a portmanteau of the 

German Bier and hydrant) retrieves the 

beer from the transfer piping and sends 

it to the taps. The Bräurosl Oktoberfest 

tent contains four Bieranten©, each 

of which is furnished with innovative 

measurement technology. The Liquicap 

M FMI51 capacitive level sensor 

monitors the level and the Picomag 

electromagnetic flowmeter monitors not 

only the flow, but also the temperature 

and conductivity. The combination of 

these three measurement parameters 

plays an important role in efficient CIP 

cleaning of the dispenser technology. 

The full potential comes to bear first 

and foremost with the gastronomy 

Jack-of-all-trades. Pocket-sized Picomag for simultaneously measuring flow, temperature and conductivity. 


technology however, since it has to 

be cleaned every 14 days at the latest, 

and then documented with the help of 

the conductivity measurement value. 

Where several instruments might be 

needed for monitoring the parameters, 

now a single device – the Picomag from 

Endress+Hauser – takes over this task. 

The instrument’s compact dimensions 

are advantageous in tight installation 

spaces. The Picomag furthermore 

comes with an integrated IO-Link 

interface as a standard feature and can 

be easily integrated into common field 

bus systems. Cloud connectivity is also 

simple to establish. 

Delivery of the beer via the 

technology container – the 

control center of the central 

beer supply system for the 

festival tent 

Beer transfer takes place via the 

technology container. The tanker truck 

is connected to the central supply 

system on the beer and gas side via 

hoses. The beer volume is determined 

with a custody transfer system. 


25

Processing 

Since the tanker trucks and beer tanks 

are connected on the gas side (gas 

pendulum process = equal pressure), a 

pump is needed to transfer the beer to 

the tanks (capacity, 3 x 28,000 liters), 

which are installed on a stainless steel 

frame approximately 4 meters above 

the technology container. When the 

system is in the “festival tent” operating 

mode, the three tanks simultaneously 

and continuously feed the transfer 

piping. From there the beer is fed to the 

dispenser taps via the four Bieranten©. 

To compensate for the reduced pressure 

in the system caused by the falling levels 

in the tanks, the pressure is regulated 

and kept constant with CO2 gas, which 

is monitored by the Deltapilot FMB50 

hydrostatic level instrument. The three 

beer lines to the tanks are equipped 

with Liquiphant M FTL50H vibration 

point level switches, which trigger 

the empty tank notification when the 

beer is removed from the tanks at the 

conclusion of the Oktoberfest. 

Monitoring the keg beverages 

Apart from the festival beer, the tent 

offers other beverages delivered in 

kegs. Whether non-alcoholic beer, soft 

drinks, mineral water, Paulaner Spezi 

(a mixture of cola and orange soft 

drink) or Shorle (apple juice mixed with 

carbonated water), an Endress+Hauser 

instrument is responsible for monitoring 

the flow at each tap. The Bräurosl tent 

thus has 30 Picomag flowmeters with 

integrated IO-Link interfaces for the keg 

beverages. The instruments monitor 

three parameters in this environment as 

well: flow, temperature and conductivity. 

The Bierant© is equipped with innovative instrumentation: the Liquicap M FMI51 for continuous 

level monitoring and the Picomag (nominal diameter DN 20) for monitoring flow, temperature and 

conductivity. 


the next day using the data captured 

by the instruments – relaxed and 

worry-free. This ensures no beverage 

shortages and no thirsty visitors. 

But that’s not all. At the end of a largescale 

event such as the two-week 

Oktoberfest, the captured data can be 

used to carry out a detailed analysis. 

Optimizing beverage consumption and 

personnel resources at future events 

thus becomes child’s play. 

Brewing engineer Uwe Daebel next to the Bierant©, the centerpiece of the beverage supply system. 


All important information at a 

glance 

How do you reliably maintain a focus on 

the beverage supply system? It’s easy: 

either by viewing the display monitor 

(Maß-o-Meter) in the technology 

container located on site, or via the 

comfort of a cloud connection from any 

location. All Endress+Hauser Picomag 

instruments are furnished with an IO- 

Link interface as a standard feature. 

The current value is continuously 

transmitted to the IO-Link master and 

then passed to the cloud. That means at 

the end of an Oktoberfest day, Paulaner 

can order the volume of beverages for 

26

ZKZ 62006 

12.09.22 15:54 

Processing 

chnology 

and food 






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- Technology & Marketing - 

27

Packaging 


by MARTINA SCHILI 

Traditional beer specialties 

Beer lovers in South West Germany are 

familiar with these traditional brands: 

Dinkelacker, Wulle Biere, Schwaben 

Bräu, Sanwald, Cluss or Haigerlocher. 

They are all regional beer specialties, 

each with its own character, and are 

brewed by Dinkelacker. The family 

The independent Dinkelacker brewery is family-owned and still brews beer in the same location in 

Stuttgart where Carl Dinkelacker founded the company in 1888. 

brewery has been in existence since 

1888. It was founded by Carl Dinkelacker 

in the Tübinger Straße in the heart of 

Stuttgart. And it is still headquartered 

there today. The company has always 

placed great importance on the best 

raw materials. They form the basis 

for the quality of the beers - whether 

Kellerbier in a swing top bottle, topfermented 

wheat beer or non-alcoholic 

Pilsner. This quality standard is also 

reflected in the technical components 

used in production. For this reason, 

Dinkelacker has long been relying on 

Leuze application know-how, as well as 

sensor technology that meets the most 

stringent requirements for reliability, 

robustness and hygiene. 

Strictly in accordance with 

the German purity law 

Processes in a brewery follow a 

precisely defined sequence. Thousands 

of visitors on guided Dinkelacker 

brewery tours are impressed by this 

every year. If you take a look behind 

28

Packaging 

the scenes, you can experience the 

brewing process from start to finish: 

first, 40,000 liters of brewing water 

and 8.5 tons of malt from local 

farmland are mixed to create beer 

mash. For its malt, which consists of 

barley and wheat, Dinkelacker uses 

summer barley from the Strohgäu and 

the Swabian Alp. Dinkelacker is one of 

the few breweries in the world who still 

use a strain master. When it is ready, 

the mash is pumped there and filtered. 

Experts call this the "lautering" of the 

wort. The spent brewer grains remain, 

which are then used as supplementary 

animal feed. The mash turns into wort. 

The wort is then boiled and the hops 

is added. The brewery procures this 

from Tettnang near Lake Constance. 

This is followed by the brewery's own 

selected yeast, the last ingredient of 

the beer. The beer wort runs through a 

cooler into the beer storage cellar into 

one of 39 huge storage tanks. Each 

tank contains between 300,000 and 

500,000 liters and is up to 25 m high. 

It is filled from the bottom until it is 

approx. three-quarters full, as the beer 

needs space to ferment in the tank. In 

order to deliver the finished product 

to the consumer, it is pumped to the 

filling installation. 

Indispensable sensor 

technology 

The sensors installed in the filling 

installation often look inconspicuous. 

But they are indispensable for 

efficient processes. Dinkelacker uses 

Leuze sensor technology at nearly 

every station. "To ensure fault-free 

operation, we depend on particularly 

robust and reliable sensors", explains 

Florian Fahr, Head of Technology 

at Dinkelacker. "The requirements 

for the technical components in the 

filling installation are very high. Here, 

there are strong vibrations and the 

sensors must be able to withstand 

frequent cleaning processes." Only 

selected sensor solutions can rise to 

the challenge. This is why Dinkelacker 

The beer ferments in the 39 huge storage tanks before it is pumped to the filling installation. 

Leuze multiple light beam safety devices of type MLD 500 secure the working range of the robots 

against access from outside. 

relies on the technology provided 

by the Sensor People from Leuze. 

Andreas Eberle, Local Industry 

Manager Packaging at Leuze, explains 

the advantages: "Primarily, retroreflective 

photoelectric sensors of 

the Leuze PRK series were installed 

here." This series is particularly well 

suited for applications in the beverage 

industry. The metal housing of the 

optical sensors is resistant. As a result, 

the devices can also function optimally 

in harsh environments." Furthermore, 

the optically switching devices even 

detect highly transparent objects 

such as bottles, due to the reflection 

principle. High-gloss plastic crates with 

different imprints are also detected. At 

Dinkelacker, the technology provided 

by Leuze has proven its high reliability 

in practice, as Andreas Eberle knows: 

"Many of the sensors have already 

been working in the family-owned 

brewery with great precision for 

decades. Some were installed at the 

end of the 1990s, some at the start 

of the 2000s." Another advantage: 

by focusing on one sensor series, the 

brewery has to stock fewer different 

spare parts and in the rare event of 

a defect, they can react quickly and 

exchange sensors easily. And if there 

should be an urgent problem, they 

appreciate the close proximity to the 

headquarters of the Sensor People, 

who will promptly offer support. 


29

Packaging 

Material flow without jamming 

or collisions 

The Leuze sensors are used at different 

points in the filling installation and 

they have specific tasks. The process 

starts in the filling installation with the 

cleaning of bottles, beer crates and 

barrels. Cleanliness and hygiene play 

an important role. "The PRK optical 

sensors are installed on the individual 

conveyor sections and detect 

pallets, barrels, beer crates or even 

bottles", explains Frank Karle, Head 

of Electrical Workshop at Dinkelacker. 

"Thus the speed of the conveyor 

belts is automatically regulated to 

prevent jamming and collisions." In 

the barrel filling section, Dinkelacker 

has installed approx. 100 sensors on 

the conveyor belts. Up to 240 barrels 

an hour are cleaned and filled there. 

Two new robots which look like a full 

beer glass support the employees: 

they lift the empty or full barrels and 

place them on the conveyor belt or 

on pallets. Dinkelacker newly installed 

the robots while the hospitality sector 

was shut down during the Corona 

pandemic. Leuze safety technology 

also has a part to play at the robots: 

multiple light beam safety devices of 

type MLD secure the working range 

against unauthorized access from 

outside. Two PRK sensors which are 

switched crosswise in front of each of 

Filled beer bottles on their way to labelling. 

the robots reliably detect an incoming 

pallet. They then start the muting 

function, which briefly bridges the 

safety light barriers so that the pallet 

can pass through. 

72,000 bottles cleaned hourly 

Empty beer crates are cleaned by 

running them through a special 

cleaning machine. The bottles, which 

were removed previously, end up in a 

large bottle cleaning machine. There, 

they are cleaned with water heated 

to 80°C - the machine can handle up 

No need for heavy lifting: in the barrel filling installation, two modern robots grip the beer barrels and 

place them on conveyor belts or pallets. 

to 72,000 bottles in one hour. Here 

too, Leuze sensors are indispensable 

for safe operation: sensors of the 

PRK series detect immediately when 

a bottle is not in line on the bottle 

cleaning machine. Then they stop the 

machine. Again, access is monitored 

by safety light curtains. After cleaning, 

each bottle is checked for residues. If 

there are any residues in the bottle 

after the first pass, or remnants of 

labels are still adhering to the outside, 

the bottle is put through the bottle 

cleaning machine for a second time. 

If this is still the case afterwards, 

the bottle is rejected. This means: "If 

beer lovers want to do breweries a 

favor, they should not put anything 

in the bottles and open empty swingtop 

bottles before placing them in the 

crate", says Frank Karle. 

Freshly filled 

If the bottles are undamaged and 

completely clean, they are filled. Leuze 

sensors make it possible to regulate 

the conveyor belt speed. The system 

calculates the optimal speed based on 

the spacing between two bottles. The 

reusable bottle installation then fills 

the bottles with beer. It can manage 

up to 66,000 bottles per hour. This 

corresponds to 3,300 crates. The 

swing-top bottle installation works 

on a separate production line. It fills 

30,000 bottles an hour. That means 

30

Packaging 

1,500 crates per hour. As the filling 

process continues, checks are carried 

out to see if the level of the bottle 

contents is correct. After closing, PRK 

sensors detect if each reusable bottle 

has been correctly fitted with crown 

caps or if the swing-top bottle has 

been closed correctly. This is followed 

by labeling: the bottle is aligned and 

labels are applied to the neck, front 

and back. Here too, nothing is left to 

chance: every label is checked for its 

correct position on the bottle while it is 

still in the machine. 

Every crate in view 

Then the crater starts its work. The 

machine fills several crates at once 

with 20 beer bottles each. Leuze sensor 

technology is also employed at this 

station: "During full-crate monitoring, 

sensors detect in a fraction of a second 

Here, the swing-top bottles are aligned as the beer crates are filled. For this purpose, one Leuze sensor 

per bottle detects the position of the label. 

if a crate is completely filled", explains Andreas Eberle. "If a bottle is missing or in a horizontal position, the crate is rejected 

and the error is corrected manually by an employee." When crates are filled with swing-top bottles, they are also aligned so 

their labels face outwards, for a pleasing look. Leuze sensors detect the labels on the bottles and support the machine with 

the correct positioning. This is followed by the last step: 

the crates are placed on pallets and delivered. Here too, 

sensors are used for presence detection of the pallets and 

optimize the material flow. 

Continued tradition 

Six widely known brands, beers for every taste and 

production which is virtually fully automated and fills 

many thousands of bottles and quite a number of barrels 

per hour: the Dinkelacker family-owned brewery from 

Stuttgart has successfully transitioned into the modern 

age. The Sensor People from Leuze make an important 

contribution to efficient production in all process steps, 

with their reliable and robust sensors. These are things 

Retro-reflective photoelectric sensors from the Leuze PRK series can 

be found in many pointsin the filling installation - here, they record 

every single bottle in a fraction of a second. Even highly transparent 

objects are not a problem for these sensors. 

Process waste. 

Recycle packaging. 


31

Packaging 

Carl Dinkelacker could not even 

have dreamed about in 1888. But he 

would have found that one thing was 

unchanged even after 135 years: the 

passion for brewing beer from regional 

ingredients to the highest quality 

standards. 

The Author 

Martina Schili is Corporate Communications 

Manager at Leuze electronic GmbH & Co. KG 

Ensuring efficient processes in the filling installation (from left): Florian Fahr, Head of Technology 

(Dinkelacker), Frank Karle, Head of Electrical Workshop (Dinkelacker), and Andreas Eberle, Local 

Industry Manager Packaging (Leuze). 

Here, filled and labelled swing-top bottles are placed into crates. The machine fills several beer crates at the same time. 

32

12.09.22 15:54 


hnology 

d food 

ZKZ 62006 





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Packaging 

First 5-liter party keg made of CO 2 

reduced tinplate 

The German tinplate manufacturer 

thyssenkrupp Rasselstein will launch 

the world’s first 5-liter keg made of CO2 

reduced bluemint® steel together with 

the German companies Kleemann and 

Westerwald Brauerei in May. 

In the joint project, thyssenkrupp 

Rasselstein will supply the CO2 

reduced packaging steel, Kleemann will 

produce and print the kegs, and the 

Hachenburger brewery will use 100% 

aromatic hops for the production and 

filling. 

Use of new bluemint® steel 

“In the production of the new bluemint® 

packaging steels, we are clearly focusing 

on CO2 reduction: By using biomethane 

and specially processed steel scrap, 

we can save up to 69% of our CO2 

emissions, making packaging steel even 

more sustainable.” explains Dr. Peter 

Biele, CEO of thyssenkrupp Rasselstein 

GmbH. Packaging steel is also a 

European leader in terms of recycling 

rates: 85.5% of tinplate packaging is 

recycled. This makes tinplate packaging 

the most recycled packaging material in 

Europe. 

By using bluemint® steel in the 

production of the beer kegs, Kleemann 

has been able to significantly reduce 

its Scope 3 emissions. “We are very 

happy to be involved in the project of 

the world’s first CO2 reduced party keg,” 

says Michael Fürst, Managing Director 

of metal packaging manufacturer 

Kleemann. As a family-run company, 

Kleemann is committed to the issues 

of sustainability and environmental 

awareness: Kleemann is aware of the 

responsibility it bears with regard to 

its future as well as future generations. 

Therefore, decisions are always made 

taking all economic aspects and 

ecological values into account. 

“Kleemann is a partner with whom we 

have been working for years. Longterm 

partnerships at eye level are our 

aim. Thanks to sustainable raw material 

and a reliable partner for Westerwald 

Brauerei, I see our 5-liter party kegs 

well-positioned for the future,” says 

Jens Geimer, Managing Partner of 

Westerwald Brauerei. The 5-liter party 

keg is a successful concept of the familyowned 

brewery from the Westerwald. 

By switching its 5-liter party kegs to 

bluemint© steel, Westerwald Brauerei 

can further reduce its carbon footprint. 

Ambitious goals of the 

companies 

Westerwald Brauerei is already climate 

neutral according to Scope 1, 2 and 3 

thanks to compensation and would 

like to achieve this on its own by 2030 

by generating more energy than it 

consumes. 

34

Packaging 

thyssenkrupp also has very ambitious 

targets: The German steel manufacturer 

aims to be completely climate-neutral 

by 2045. “We have been selling the 

first volumes of our new, CO2 reduced 

tinplate since 2022,” states Dr. Peter 

Biele, CEO of thyssenkrupp Rasselstein. 

“We will invest a lot in the next few years 

to achieve our climate targets,” adds 

CEO Dr. Peter Biele about thyssenkrupp's 

transformation. In March thyssenkrupp 

Steel awarded the construction of a new 

hydrogen-based direct reduction plant 

with two innovative smelters to the SMS 

Group. 

About thyssenkrupp 

Rasselstein: 

thyssenkrupp Rasselstein GmbH is 

one of the world's leading suppliers of 

high-quality, precision-manufactured 

packaging steel. The site in Andernach, 

Germany—the world's largest production 

facility of its kind—produces 1.5 million 

tonnes of packaging steel annually. 

About 2,400 employees serve around 

400 customers in 80 countries in a 

variety of markets— from producers of 

food and pet food cans, to manufacturers 

of beverage and aerosol cans, packaging 

for paints and coatings or containers for 

hazardous goods, as well as crown corks 

and closures. Expert teams in service, 

sales and technical customer service 

complement the product portfolio. 

About Kleemann 

Kleemann is a family-owned company 

with a tradition of almost 150 years, 

founded in 1875 by Julius Kleemann 

in Frankfurt am Main. At the company 

headquarters in Dettingen am Main 

(Karlstein), a successful team of 

currently 130 employees is working 

on the realization of customer wishes. 

In addition to tinplate beverage cans, 

Kleemann also produces food cans and 

press-in lid pails. 

About Westerwald Brauerei 

The Westerwald Brauerei is a familyowned 

brewery and is managed by 

Jens Geimer in the 5th generation. The 

beers, which have won many awards, 

are sold primarily in the geographical 

Westerwald region and in neighboring 

regions in sophisticated restaurants 

and at well-stocked beverage and food 

retailers. The medium-sized company 

with about 80 employees and 10 

trainees is famous for brewing with 

100% aromatic hops and for the 6-week 

maturing period. For this reason, the 

Westerwald Brauerei was accepted 

into the Slow Brewer association, in 

which it is strictly certified every year. 

In addition, the family-owned brewery 

can count itself among the first German 

breweries to present a common good 

balance sheet within the common good 

economic framework, thus laying the 

foundation for the company's strategic 

orientation with regard to sustainable 

and ethical business practices. Since 

October 2021, the medium-sized brewery 

has also been 100% climate neutral 

by compensating for emissions with 

a certified climate protection project 

according to Scope 1, 2 and 3. The entire 

“Brewery Experience” and its adjoining 

Beer Park can be visited at any time— 

even all the production rooms—because 

transparency is a matter which is close 

to their hearts. 


35

Packaging 

Markem-Imaje’s Brand New Coding 

Innovations Impress Industry at 

interpack 2023 

Markem-Imaje (MI), the global 

provider of end-to-end supply chain 

solutions and industrial marking and 

coding systems for multiple market 

verticals, unveiled market-first new 

coding technology designed to propel 

production of serialized 2D barcodes, 

three recently-developed laser designs 

and a host of other innovations at 

interpack this year. 

Amid the packaging industry’s biggest 

global event in six years, MI’s stand 

stood out for the variety and level of 

innovation on display: many of which 

were designed since the last interpack 

edition, including the revolutionary 

new Super Piezo Inkjet (SPI) marking 

technology. 

“This new technology combines the 

advantages of continuous inkjet CIJ 

and Drop on Demand,” says Markem- 

Imaje CIJ Product Division Director 

Sabri Mourad. “It’s coming to answer 

the demand of brands to have high 

quality print on the product and to 

serialize 2D codes. This is the right 

answer to the revolution coming to 

the market in 2D barcodes from GS1. It 

will give brands the capability to mark 

unique brands with unique codes on 3D 

complex surfaces”. 

Besides SPI, Markem-Imaje 

demonstrated three recentlydeveloped 

laser models, one to 

respond to the industry demands of 

the segment’s three technologies, 

each helping brands to meet their 

sustainability goals whilst boosting 

productivity at a time when 

manufacturers face an increasingly 

challenging environment. 

MI’s new ultraviolet technology, the 

UV500, excels on difficult materials 

where other laser technologies cannot 

perform so well, including on the finest, 

easily-damaged substrates like new 

more environmentally friendly thinner 

mono films, as well as polymer labels 

and thermoplastics like High-density 

polyethylene (HDP). 

“interpack 2023 was a great 

opportunity to meet our customers 

and partners again and start 

new projects and collaborations,” 

comments Andreas Grabotin, Zone 

Director for host country Germany, 

Switzerland and Austria at Markem- 

Imaje. “Solutions in our booth focused 

on sustainability, digital innovation, 

traceability and efficiency. Our visitors 

showed particular interest in our endto-end 

solutions, driving sustainability 

KPIs, reducing waste and protecting 

consumers and brands,” he adds. 

Indeed, a key attraction at MI’s stand was 

an in-line packaging line demonstration 

featuring laser, continuous inkjet, 

thermal transfer overprinting, large 

character inkjet, and intelligent print and 

apply labeling systems in action. The 

demo was fully integrated and managed 

by MI’s Packaging Intelligence software 

suite CoLOS®, prepared for supply chain 

traceability and engaging consumer 

experiences. 

This year, for the first time, Markem- 

Imaje also co-sponsored the first of 

interpack’s seven SPOTLIGHT Themes & 

Trends talks on Logistics: Optimization 

in Uncertain Times, on the opening day, 

and delivered the keynote speech. The 

event saw 143,000 in-person visitors 

between 4-10 May with another 200,000 

watching events online, as well as 2,807 

exhibitors. 

36

Packaging 

GREEN EFFICIENT TECHNOLOGIES 

The independent media platform for 

energy supply, efficiency enhancement and 

alternative energy sources and storage 

Sustainable opportunities in process 

technology 

Circular economy in the industrial 

production process 

Topics H 2 

, Synthetic Fuels, Water, 

Solar & Photovoltaics, Wind Power, 

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Dr. Harnisch Verlags GmbH · Eschenstr. 25 · 90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0 · info@harnisch.com · www.harnisch.com 

37


Nearing the finish line: Vetropack 

Starts up Furnaces in New Plant in 

Northern Italy 

After a construction period of one and a half years, glass manufacturer Vetropack has 

begun the process of heating up the two melting furnaces at the new Boffalora sopra 

Ticino plant in Italy. The furnaces will be gradually brought up to temperature and filled 

over the course of several days in preparation for the start of production. Upon its official 

inauguration in October 2023, Vetropack’s new high-tech plant will be producing up to 70 

percent more glass than the previous plant, while maintaining maximum flexibility and 

sustainability. 

Vetropack Italia S.r.l., a subsidiary 

of the Vetropack Group, has been 

producing glass packaging in Trezzano 

sul Naviglio in northern Italy. Now the 

company is relocating production to its 

new state-of-the-art facility in Boffalora 

sopra Ticino, located 25 kilometers 

away. Vetropack has invested more than 

CHF 400 million in the new production 

site, in order to stay ahead of rising 

demand in the Italian market and 

meet increased quality requirements. 

"The Italian market, with its many 

global brands, plays a major role in our 

strategy," explains Johann Reiter, CEO 

of the Vetropack Group. "With the start 

of the commissioning phase, we have 

reached an important milestone in Italy. 

Even though there are still a few steps 

to go before production starts – we are 

approaching the finish line." 

The state-of-the-art filtration system in Boffalora sopra Ticino keeps up with the size of the production facilities – and is expected to noticeably reduce dust 

and nitrogen oxide emissions. 

38


Using energy with precision 

Prior to heat-up, Vetropack conducted 

a "cold" acceptance inspection of the 

new furnaces in Boffalora, both outside 

and inside. The subsequent 24-hour test, 

also carried out "cold", confirmed that 

the furnace equipment is functioning 

optimally. On May 22, the first furnace 

was fired up, with the second furnace 

following a few weeks later. Initially, 

external burners are firing the furnaces. 

This process takes a total of 14 days: "The 

furnaces must be heated up from room 

temperature to 1550 degrees Celsius 

in a precise and controlled manner. 

We follow a previously calculated 

heating curve to prevent the furnaces 

from suffering any damage," explains 

Christoph Burgermeister, project 

manager at Vetropack. "In addition, 

the refractory material expands as a 

result of the heating, so we have to 

continuously adjust the pressure pins 

With 347,000 m2, the new plant in Boffalora sopra Ticino is one of the largest in the Vetropack Group. 

in the steel structure during this step of 

the process." 

Once the furnaces have reached an 

internal temperature of approximately 

1050 degrees Celsius, the furnace 

burners are activated to raise 

the temperature to 1550 degrees 

Celsius. Filling begins with waste 

glass cullet, which not only saves 

The burners of the furnaces are supplied with natural gas. 


39


valuable resources but can also be 

melted down with less energy input 

than raw material. After two to three 

days, the cullet is supplemented by a 

mixture of primary raw materials and 

finally heated for about 24 hours. 

Thereafter, the molten glass passes 

via the forehearth into the feeders and 

through the working end, then is cut 

into glass gobs and fed in sequence to 

the automatic glass container forming 

machines. Depending on the progress 

of the commissioning, Boffalora's 

schedule foresees the start-up of the 

forming machines sequentially and 

closely together. 

Flexible and sustainable production 

According to Vetropack, the new plant 

will not only offer up to a 70 percent 

increase in production capacity 

compared to the Trezzano plant. The 

smart technologies in which the Swiss 

glass manufacturer is investing for the 

Boffalora brownfield project will also 

enable greater production flexibility, 

for example for so-called semi-specials 

– containers that differ from the norm, 

in smaller batches. In addition, the site 

is geared towards a significantly more 

resource-efficient and sustainable 

In the "cold end" of the plant, once moulded, the containers pass through the annealing furnaces and 

are then subjected to quality tests. 

production, with the water used for 

production and exhaust heat from the 

melting furnaces recycled as far as 

possible through recirculation systems, 

and emissions greatly reduced through 

the latest filter systems. 

With the new site opening, the previous 

plant in Trezzano sul Naviglio will be 

closed down. Boffalora sopra Ticino will 

remain as the sole Vetropack site in Italy. 

However, the 301 employees will not have 

to fear for their jobs, as all staff members 

of the previous site have been offered 

a transfer. With the significant increase 

in productivity, the current workforce, 

which already includes employees hired 

in the recent past to secure the necessary 

training, will continue to grow to meet 

production needs. 

In the so-called "hot end" of production, the containers, made of cullet and primary raw materials, are produced by forming machines at a temperature of 

approximately 1100 °C 

40


16-19 July 

Chicago, IL, USA 

IFT Food Expo 

Institute of Food Technologists 

252 W. Van Buren, 

Suite 1000, Chicago, IL 60607 

Tel.: +1-312-782-8424 • Fax: +1-312-782-8348 

www.ift.org 

26-28 September 

Nuremberg, Germany 

Powtech 

NürnbergMesse GmbH 

Messezentrum,90471 Nuremberg 

Tel.: +49 911 86 06 49 09 • Fax: +49 911 86 06 49 08 

www.powtech.de 

7-9 November 

Dubai, UAE 

Gulfood Manufacturing 

Dubai World Trade Centre, 

P.O. Box 9292, Dubai, UAE 

Tel: (+971) 4 308 6124 

info@dwtc.com 

www.gulfood.com 

8-30 November 

Frankfurt, France 

Food ingredients Europe 

Informa Markets 

PO Box 12740, de Entree 73, 

Toren A, 1100 AS Amsterdam Zuid Oost, 

The Netherlands 

Tel.: +31-20-409 9544 • Fax: +31-20-363 2616 

www.figlobal.com 

28-30 November 


Brau Beviale 

NürnbergMesse GmbH 

Messezentrum, 

90471 Nuremberg 

Tel.: +49 911 86 06 49 09 • Fax: +49 911 86 06 49 08 

www.brau-beviale.de 

* This list of events is accurate, to the best of 

our knowledge. However potential visitors are 

recommended to check with the organizer since some 

details are subject to change. We make no claims to 

be complete and are grateful for any corrections or 

completions. Please contact: drink@harnisch.com 


41

12.09.22 15:54 

Suppliers’ Guide 

Air Conveyors & Silos 

POSIMAT 

P.O. Box 306, Av. Arraona, 23 

08210 Barberà del Vallès/ 

Barcelona,Spain 

Tel: +34-93-729-7616 

E-Mail: sales@posimat.com 

www.posimat.com 

Aseptic & Hygienic Valve 

Technology 

Equipment 

E-Mail: 

machinery@drink-gmbh.com 

www.drink-gmbh.com 

CO 2 Testing, 

Pilot Plant 

CO 2 Testing & Pilot Plant 

Individual extraordinary SERVICE for you 

Focus is: Equipment to produce and mostly bottling / packaging 

of beverages second hand + new 

We have access to almost all used machines available on the 

market. 

WE ARE ABLE TO RATE IT for you 

• consulting / planning 

• organization / documentation 

• relocation / modification 

If you have already Krones / KHS / Sidel machines older than 5 

years, or you are looking for second hand 

WE WILL BE DEFINITELY YOUR PARTNER 

Detergents & Disinfectants 

Original valve solutions 

since 1879 

Phone +49 7361 5702-0 

www.rr-rieger.com 

beta-Glucan Analysis 

Zahm & Nagel Company Inc. 

210 Vermont Zahm & Street Nagel Company Inc. 

PO Box 210400 

Vermont Street 

Holland, PO New Box 400 York 14080 USA 

Tel: +1-716-537-2110 

Holland, New York 14080 USA 

Fax: +1-716-537-2106 

www.zahmnagel.com 

Tel: +1-716-537-2110 

Fax: +1-716-537-2106 

www.zahmnagel.com 

Consultancy 

Murphy & Son Ltd. 

Alpine Street 

Old Basford, Nottingham, NG6 0HQ 

Sales: +44-115-978-0111 

Technical enquiries: +44-115-978-2728 

sales@murphyandson.co.uk 

Exhibitions & Tradefairs 

NovaBiotec® Dr. Fechter GmbH 

Goerzallee 305 a 

14167 Berlin, Germany 

Tel: +49-30-84718-410 

Fax: +49-30-84718-450 

glucantest@novabiotec.de 

www.novabiotec.de 

Beverage and Packaging Experts 

CAPE DECISION sprl 

avenue de la Métairie, 9 

Sept Fontaines 

B-1420 Braine l'Alleud, Belgium 

Tel/Fax : +32 (0)2 354 86 38 

www.capedecision.com 

Messe München GmbH 

Messegelände 

81823 München, Germany 

Tel: +49-89-949-11318 

Fax: +49-89-949-11319 

www.drinktec.com 

Fibers 

ss technology 

ge and food 

ZKZ 62006 






drinkworld is the leading magazine for the 

entire drinks industry worldwide. Feature 

articles and short communications cover the 

whole spectrum of : 

• processing 

• bottling 

• ingredients 

• logistics 

• packaging 

• marketing 

We establish a longtime advertising effect for 

your company or for your services by been 

ever-present on the market. 

Feel free to contact us for more information: 

drink@harnisch.com 

Gable Top & Aseptic Packaging 

Evergreen Packaging Inc. 

2400 6th St. SW 

Cedar Rapids 

IA 52404, USA 

Tel: +1-319-399-3200 

Fax: +1-319-399-3543 

evergreen.packaging@everpack.com 

www.evergreenpackaging.com 

42

Suppliers’ Guide 

Gase 

Process Aids 

3300_ANZ_Logo_Adresse_Drink_RZ.qxd:Layout 

Water Treatment 

Freshline UK 

Air Products PLC 

2 Millennium Gate 

Westmere Drive 

Crewe 

CW1 6AP 

Phone: +44-800-389-0202 

Fax: +44-1932-258502 

freshli@airproducts.com 

Pectins 

Murphy & Son Ltd. 

Alpine Street 

Old Basford, Nottingham, NG6 0HQ 

Sales: +44-115-978-0111 

Technical enquiries: +44-115-978-2728 

sales@murphyandson.co.uk 

Steam Boilers 

Grünbeck Wasseraufbereitung GmbH 

Industriestr.1· 89420 Hoechstaedt ·GERMANY 

Phone +49 9074 41-0 · Fax +49 9074 41-100 

www.gruenbeck.de · info@gruenbeck.de 

Clear Water = Clean Environment! 

Experience of over 20 years in water management. 

Clean. Safe. Sustainable! 

AQUA TECHNOLOGIE NÖRPEL 

ATN Aqua Technologie Nörpel 

Langer Graben 34 

D-71297 Mönsheim 

Fon +49 7044 91584-0 

Fax +49 7044 91584-99 

wasser@atn-wasseraufbereitung.de 

www.atn-wasseraufbereitung.de 

Treatment 

Conservation 

Disinfection 

Depolluting 

Bezugsquellen_45x58_RZ_schatten.indd 1 

01.03.2012 11:53:23 Uhr 

Printing and Labelling 

Turnkey lines for 

concentrate production 

Wort/Malt Quality 

Labelling systems • Labelling software • Barcode 

and Industrial printers for the beverage industry 

Logopak Systeme GmbH & Co. KG 

Dorfstraße 40 I 24628 Hartenholm 

Telephone +49 (0) 41 95 99 75-0 

po@Logopak.de I www.Logopak.com 

NovaBiotec® Dr. Fechter GmbH 

Goerzallee 305 a 

14167 Berlin, Germany 

Phone: +49-30-84718-410 

Fax: +49-30-84718-450 

glucantest@novabiotec.de 

www.novabiotec.de 

20190503_RZ_Anzeige_Getraenke_Technologie&Marketing_60x40mm.indd 03.05.2019 09:29:58 1 

ISSN 1433-1594 

Publishing Company: 

Dr. Harnisch Publications 

Eschenstr. 25 

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Phone: +49 (0) 911 2018 - 0 

Fax: +49 (0) 911 2018 - 100 

drink@harnisch.com 

www.drink-tm.com 

Editor-in-Chief: Ian D. Healey 

Phone: +49 (0) 911 2018 - 215 

ihealey@harnisch.com 

Publisher: Benno Keller 

keller@harnisch.com 

International Communications: 

Gabriele Fahlbusch 

fahlbusch@harnisch.com 

Editorial team: Donna Berry, 

Sebastian Martinek, Brigitte Haulena 

Copy Editing: Nicholas Somers 

Art Director: 

Bruno Bozic 

bozic@harnisch.com 

Technical Manager: Armin König 

Subscription: Marta Bletek-Gonzalez 

Reader Service: Sabrina Maasberg 

Media planning: 

Steve Max (North America) 

steve.max@harnisch.com 

Thomas Mlynarik (Germany) 

mlynarik@harnisch.com 

Carola Weise (Western Europe) 

weise.harnisch@web.de 

Digital: 

Britta Steinberg 

steinberg@harnisch.com 

Subscription Information: Qualified Readers, 

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43

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