07.388 KHS Journal 02_07_e

Transcription

KHS journal
2° 2007
English
World Innovation INNOFILL DNRV:
fully automatic, flexible, hygienic
Historical Budweiser
Budvar brewery
A Masterpiece Filler
Time for Quality
Wrap-around and Trays:
New Innocoll hot melt
The Super Adhesive
Knorr Vie Offers
Vitamins in a Bottle
THE WELLNESS KICK
editorial
KHS ON THE LASTING ROAD TO SUCCESS:
SYSTEMATIC UPSWING
Valentin Reisgen,
Chief Executive Officer of KHS AG
Dear Readers,
“Don’t forget: success is the reward of hard work,” exhorted the Greek poet Sophocles almost two and a half thousand years ago. He was
right. We are currently experiencing this in the KHS Group. At the end of 2005, together with our staff, we introduced the program of
change 2010plus – the strategic pointer for the whole company for a common approach to the market, systematic customer orientation,
worldwide quality standards, and the establishment of a new internal structure. A great deal of work has gone into this project with ultimately only one goal: to satisfy the customer by meeting his expectations.
To come straight to the point, the program is far from completed. Without defining a particular timeframe, the program is in any case an
ongoing process of improvement of an internationally active turnkey supplier. We can now
clearly see, however, that our joint efforts are bearing fruit in the long term.
KHS GROUP IN THE FIRST HALF OF 2007:
The 2006 financial year alone has shown a satisfactory six-percent increase in sales with a
* Turnover € 520.3 million (+ 46.7%)
noticeably improved EBIT. This excellent growth, which continued in the first half of 2007,
* Order receipts € 479.4 million (+ 46.6%)
is now turbocharged. Compared with the same period of last year, turnover has increased
* EBIT € 19.1 million (+ 107.6%)
46 percent to €520 million. And the orders received have has also increased tremendously,
likewise by nearly 50 percent to €479 million. At around €19 million, the operating profit
has been correspondingly pleasing, twice that of the first half of 2006.
An overall very positive development, which shows that the customers in the beverage, food, and non-food sectors are registering our
efforts worldwide and are rewarding this continuous show of strength by placing their trust in KHS products and solutions. Of course, we
know that the favorable global world economic situation has contributed to the success of our actions and plans, and that such pleasing
growth will have its limits with a possible (and expected) future swing of the economic cycle in the other direction. However, the lasting
upswing at KHS is above all systematic, and will continue positively within the given economic conditions. This will be ensured by the confidence of our customers in leading technology and know-how made by KHS and the great and dedicated efforts of our employees. For,
as Louis Pasteur has already said, “Determination opens the door to success.”
Yours sincerely,
PS: Someone who has for many years contributed with untiring and quite extraordinary commitment to the success of KHS is Mark Arrant,
who until the beginning of July was President of KHS USA. For personal reasons (because his health is of paramount importance), Mark
has now handed over his post to his colleague of many years, Mike Brancato. Fortunately, however, he will continue to be of service to
KHS and his customers as Executive Vice President of KHS USA. Thank you, Mark. We wish you all the best!
» The very positive development shows that the customers in the beverage,
food, and non-food industries are registering our efforts worldwide.
«
contents ° 2°2007
people+markets
04
08
news
Customers, Know-How, and Contacts
04
dossier
12
Innocoll: New KHS hot melt for wrap-around and tray packs
The Super Adhesive
dialog+opinion
16
Interview with XIAO Derun, Chairman of the China Brewing Association
“Here in China, we like to rely on German know-how”
16
task+solution
20
Historical Budweiser Budvar brewery invests in the future
Time for Quality
24
Wellness product Knorr Vie: KHS is turnkey supplier
La Vie en bouteille
28
Kofola’s extraordinary success story
Adept Keg-Tech
31
Krombacher Brauerei explores new avenues
The Fresh Keg
32
Ukraine: Olimp sends spirits subsidiary Prime on a road to success
The Prime of Vodka
36
Sarajevo Brewery relies on multi-function ACF technology
Triple Jump
40
Bosnia and Herzegovina: Vitaminka in the passing lane
Conqueror of the Peak
24
36
technology+innovation
43
Innoket ROLAND 5/2 H offers maximum flexibility
The Versatile One
44
KHS plant concept: Customized conveying system
A Dolly for All Eventualities
47
World innovation Innofill DNRV: fully automatic, flexible, hygienic
50
Perfect upgrades for older machines and equipment
Fountain of Youth
52
New plant information system PMS
The System of Systems
56
Technical terms in practice
What is Viscosity?
47
56
Guest at KHS
59
Welcome to Prague
59
02*03
Left Enthusiastic guests came to Kleve from
around the globe. Right Interested spectators:
gripping technology from KHS.
KHS PLANT AT KLEVE CELEBRATES 50TH ANNIVERSARY
THE PACKAGING ARTISTS FROM RHINELAND
The wrapping of the Reichstag in Berlin by
Christo and Jeanne-Claude was undoubtedly a work of art. But what about a company that has been presenting itself consistently and successfully as a globally recognized packaging specialist for the beverage,
food and non-food industries for 50 years?
The answer is simple: 50 years of state-ofthe-art technology, 50 years of continuous
new and further development, 50 years of
top quality, 50 years of having an ear for the
market, and 50 years of customer service.
This description fits the KHS Kisters plant
in Kleve, North Rhine-Westphalia, Germany.
Fifty years of company history – the
perfect occasion for celebrations. Between
28 and 30 June 2007 a number of special
events was organized for customers from
around the world, employees, and the public. Events included open house, guided
tours of the plant, presentations, entertainment for children, raffle, and a special inhouse exhibition.
A fact many of the guests have been
aware of for a long time is that strengthening or enhancing packaging is a key component of today’s retail and business activities. Packaging should be application-oriented, attractive, inexpensive and quick to
produce, robust, and also environmentally
sound. The KHS product range facilitates
all these features. It includes proven traditional packaging technology and advanced
innovations such as shrink packers, pad
shrink packers, tray shrink packers, tray
packers, wrap-around packers, or wraparound shrink packers.
In Kleve, where in 1957 the firm
’Kisters Maschinen- und Apparatebau’ started
as a small regional machine manufacturer,
now stands a plant occupying an area of
some 60,000 square meters with a staff of
284 employees including 14 trainees.
As early as 1968, when the company
was renamed to ’Karl Kisters Maschinenbau
GmbH’, it started concentrating on packing
machines for the beverage and food industries, thus laying an important foundation
stone for the continuation of the company’s
success story. From 1978, the company pioneered the application of microprocessors
for machine control purposes. In 1987,
shares of the company stock were sold to
Klöckner Mercator Maschinenbau GmbH in
Duisburg, and the company changed its name
to ’Kisters Maschinenbau GmbH’. In 1990,
’ZVT Verpackungstechnik’ was established
at Bad Arolsen. In 2002, the firm was ultimately fully integrated into the KHS group.
Plant Manager Karl-Friedrich Böhle
sums it up, “On the occasion of the 50th
anniversary of our company we look back on
a success story without equal. For the most
part, we owe this to the courage and farsightedness of the company founders, Maria
and Karl Kisters. Following the integration
into the KHS Group we are today part of an
international big player in the field of filling and packaging technology and therefore
excellently positioned for the future.” The
basis for everything, if one may say so, is the
art of perfect packaging engineering – with
all due respect to the Reichstag wrappers.
Maternus Gemmel (left), Chief Sales Officer, talking with Maria and Karl Kisters.
people+markets ° news
04*05
BEER CONSUMPTION
A 100-MILLION-HECTOLITER PLUS
Almost 1.7 billion hectoliters of beer were brewed worldwide in 2006, 100 million hectoliters or about 6 percent
more than in the previous year. This is according to the
latest ’Barth-Bericht Hopfen 2006/07’ [Barth Hop Report]
published by the Nuremberg-based hop trader, Joh.
Barth & Sohn. The Nurembergers should know – after
all, the company is one of the largest hop traders in the
world with a market share of 35 percent. Almost half
of the growth can be attributed to China followed by
Vietnam, Thailand, Mexico, Brazil, Peru and Venezuela,
Russia, Romania, Ukraine, Nigeria and South Africa.
“This clearly shows where the greatest potential for the
future lies, namely in Asia, South America and Africa,”
asserts the Managing Partner of Joh. Barth & Sohn,
Stephan Barth.
SOUTH KOREA
NEW DRINK IDEA FOR BABIES
Baby swimming, baby yoga, baby gymnastics – these
have all inspired the South Korean company Maeil Dairy
to produce a quite special drink: Aqua Mamma – an isotonic drink for babies. Aqua Mamma is intended to help
the little ones to regain energy and electrolytes, which
are lost due to early sporting activities.
NEW: 24-HOUR SUPPORT FROM KHS USA
KNOW-HOW ON CALL
KHS service quality knows no bounds – and from now on, in the U.S.A., takes
no account of time. Whenever a customer in the States dials 866 915-5889, a
member of the KHS service staff will answer. At three in the morning or eight
in the evening. The service phone is manned around the clock. KHS specialists from the appropriate Competence Center are available to answer all questions in detail regarding filling, cleaning, process engineering or packaging
and palletizing equipment, or the beverage, food, or non-food sectors.
The spare parts service is also integrated within the hotline.
Measured by the number of production lines delivered by KHS in the
United States, KHS is today one of the preferred suppliers of the large U.S.
American beverage manufacturers. A core element of the growth strategy is
the further expansion into new markets, such as body care, foods, paints, motor
oils, and chemical products. Due to the company’s special experience, KHS is
particularly well equipped for activities in the food and non-food branches of
industry.
ECKES-GRANINI
CZECH REPUBLIC
KRUSOVICE BREWERY COMES TO HEINEKEN
Heineken is expanding its activities in the Czech Republic with the takeover of the Krusovice Brewery from the German Radeberger Group. With this transaction, the market share
of Heineken beers in the Czech Republic will increase to 8 percent (1.6 million hectoliters).
GERMANY
HERFORDER BRAUEREI GOES TO WARSTEINER
Warsteiner is consistently forging ahead with its growth strategy with the integration of
Herforder Brauerei. Herforder Brauerei is one of the best-known private breweries in Germany and is the most important brewery in East Westphalia. It records a total output of
more than 500,000 hectoliters and an annual turnover of around €50 million. “We are
progressing with our corporate goal of expanding the Warsteiner Group into a national and
international beverage association. This step is a strategically expedient and enriching
compliment to our previous portfolio,” says Professor Gustavo Möller-Hergt, General Manager of the Warsteiner Group, describing the trend.
IINVESTMENT IN SWEDEN
Eckes-Granini is further extending its position as one of the leading brand manufacturers of fruit beverages in Europe. Its latest acquisition is the 100-percent takeover
of the Swedish premium fruit juice manufacturer, Brämhults Juice AB. Brämhults is
the only producer in the northern region,
which is active in the growth segment of
chilled, locally pressed fruit juices. EckesGranini is already represented in the northern region with subsidiaries in Finland and
Lithuania.
CARLSBERG
GALLUP POLL SPRINGS A SURPRISE
PROFILE CAN FOR
GERMANY
U.S.A.: FIRST PLACE FOR BEER
Carlsberg Germany is the first of the more
than 150 ’Carlsberg countries’ worldwide
to introduce the profile can. With this
world premiere in the company, the brand
hopes to strengthen its position in Germany and open up further potential in
the growing non-refillable segment in the
international beer market. Carlsberg has
been one of the strongest growing international premium brands in the German
beer market since 2004.
INVESTMENT IN THE FUTURE
TWENTY-FIVE PERCENT MORE
TRAINING OPPORTUNITIES AT KHS
In times of declining training opportunities and the discussion of
a countrywide training levy, KHS is responding with a clear signal.
Twenty-five percent more training opportunities in Germany. As a
result, 50 trainees will start their careers at the KHS locations in
Dortmund, Bad Kreuznach, Worms, Kleve, and Kriftel in 2007. The
total number of all KHS trainees in Germany from now on will be
exactly 154. But that’s not all – the Executive Board has already
agreed to implement this increased number of training opportunities, that is to say ’25%+’, this year.
Good news for American breweries. The latest Gallup poll
has discovered that beer has become the most popular alcoholic drink in the U.S. Forty-one percent of alcohol-consuming Americans prefer beer to both wine (33 percent)
and spirits. The previous year, it was rather different when
wine pushed beer into second place from 39 to 36 percent.
RUSSIA
MILK MAKES GOOD
Packaged milk products are booming on the Russian market. The British market research institution, Euromonitor,
forecasts sales of over 8.1 billion U.S. dollars by 2011. Growth
rate: 5.6 percent annually. As well as U.H.T. milk, the institution sees outstanding opportunities for milk drinks containing fruit juice.
ANHEUSER-BUSCH
WATER FROM ICELAND
The U.S. beer concern, Anheuser-Busch, will also be selling
water in the future. The company has bought 20 percent of
the Icelandic firm Icelandic Water Holdings. The world’s
second-largest brewer is taking on the U.S. sales for the
Icelanders whose main brand is called Icelandic Glacial.
EFES BREWERIES INTERNATIONAL
KICK IN KAZAKHSTAN
Efes Breweries International (EBI) is significantly expanding its activities in Kazakhstan and is increasing the capacity of the brewery in Kazakhstan’s capital Almaty from 1.3
million to 2.1 million hectoliters. EBI is currently represented by two breweries in the country, and is the secondlargest beer producer with a market share of 21 percent.
GERMAN YOUTH
WATER AND COLA IN FASHION
Member of the Executive Board, Maternus Gemmel (2nd from the left)
together with representatives of the Joint Works Council Helmut
Weber (Chairman, 4th from the left) and Karl-Heinz Engbarth (Deputy
Chairman, 3rd from the left) and Human Resources Manager Rolf
Staab (1st from the left) welcome the new trainees during the oneweek introductory seminar in the European Academy Otzenhausen.
According to the results of the latest Youngcom! survey,
Germany’s youth aged between 13 and 20 years in particular prefer cola and carbonated mineral water (drunk by more
than 60 percent in each case). In third place are fruit spritzers
with 54 percent. According to the survey, young people
particularly go for water when they are thirsty. When they
go out, cola is their first choice.
06*07
KHS USA
MANAGEMENT CHANGE
Mark Arrant, President of KHS USA, has decided to give
up his post for personal reasons. However, Mark Arrant
will continue to act for KHS USA in the future as Executive Vice President. The Executive Board of KHS AG
regrets the resignation of Mark Arrant who has distinguished himself over many years by unexcelled commitment to the interests of KHS, and thanks him expressly
for his commendable work and exemplary dedication.
Mark Arrant will continue to be a guarantee for the success of the future development of KHS USA in his new
position.
The new president of KHS USA is Mike Brancato,
(photo) who has been working in the packaging industry for more than 20 years
and for KHS USA for five
years, most recently as
Executive Director Sales
Beverage Group. Mike
Brancato, “I would like
to thank Mark on behalf
of all our staff for the
outstanding cooperation,
and I would ask all customers to have just as
much confidence in me
as they have shown
toward Mark Arrant.”
2
NEW OFFICE
KHS OFFICE IN EGYPT
Since July 1st of this year, the KHS Group is being represented by a new office
in Egypt’s city of Cairo. The office is managed by Sherif Sabri (right). He is
assisted in supporting the customers by a further four colleagues (left to right:
Reda Hassan, George Farid, Noha Mikhail, and Ashraf Kirols). Here are the contact details:
KHS AG Office – Egypt
16, Asma Fahmy Street, Heliopolis – Cairo, Egypt
P.O. Box 5944, Heliopolis West – Postal Code 11771
Tel:
+ 2 02 2 417 85 41
Fax:
+ 2 02 2 290 90 09
E-mail: sherif.sabri@khs.com
INTERVITIS INTERFRUCTA AWARD FOR WORLD FIRST
KHS RECEIVES GOLD INNOVATION PRIZE
The Intervitis Interfructa gold innovation prize was awarded to
KHS in Stuttgart at the end of April. In the filling, capping, and
packaging technology category, KHS received the highest possible decoration for the newly developed Innofill DNRV filling system. The new KHS filling system is also something special and a
world first: it is virtually predestined for the aseptic cold filling
of non-alcoholic beverages in plastic bottles between 0.1 and 5.0
liters (all details beginning on page 47).
After the awarding ceremony (left to right): Maternus Gemmel,
Chief Sales Officer, Katja Schweder, German Wine Queen,
and Dr. Achim Wapniewski, Global Marketing Director.
KHS around the world
CUSTOMERS, KNOW-HOW, AND CONTACTS
KHS has been represented in world markets by its engineering and the proficiency of its employees
for almost 140 years. The company stands for absolute customer-orientation, problem-solving competence of its high-tech experts, and the know-how of a consulting staff that contributes expertise
on economic issues. The KHS team demonstrates this worldwide day after day.
DUNG QUAT / HANOI HAI PHONG / HUE BEER /
SAIGON BACLIEU / SAIGON BINH TAY
KHS IN VIETNAM: HIGH-TECH FOR THE BEER BOOM
The beer market in Vietnam is currently flourishing with an impressive growth rate
of 8 to 10 percent per year. KHS is an active player in this boom. This is demonstrated by the latest sales successes with leading breweries in the country:
Dung Quat: 15,000-cph canning line. The Dung Quat Brewery in Quang Ngai
City has taken delivery from KHS of a complete line for filling 15,000 beer cans
(330 milliliters) per hour.
Ha Noi Hai Phong: 15,000-bph bottling line. The Ha Noi Hai Phong Brewery
has its production plant in Hai Phong City. The company has now ordered a complete beer bottling line for refillable glass bottles. The capacity is 15,000 bottles per hour, optionally 450 or 330 milliliters.
Hue Beer: 36,000-bph bottling line. The Hue Beer Company in Hue City has
ordered an Innofill DPG bottling machine and an Innoket KL labeler to complete
its bottling line. The line is able to process 450-milliliter refillable bottles at
36,000 bottles per hour.
Saigon Baclieu: 15,000-bph refillable glass line. The Saigon Baclieu Beer
Joint Stock Company in Bac Lieu Town in the province of Bac Lieu is taking delivery of an extensive refillable glass line. Output: 15,000 bottles per hour (355
and 450 milliliters).
Saigon Binh Tay: 33,000-cph canning line. KHS is supplying a system to the
Saigon Binh Tay Brewery in Binh Duong province comprised of an automatic can
depalletizer, an Innofill DVD 40 filler, pasteurizer, an Innopack CA case opener,
packer, sealer, and palletizer as well as the associated peripherals. The line will
process 33,000 330-milliliter cans per hour.
LION NATHAN BREWERIES, SYDNEY
THREE NEW GENERATION INNOPAS C
The Australian group, Lion Nathan Breweries, is
focusing fully on the new generation of double-deck
Innopas C pasteurizers from KHS. The company has
ordered three of the trend-setting pasteurizers (Innopas
P II SC):
* for Tooheys in Lidcombe Sydney, two pasteurizers
for 108,000 375-milliliter non-refillable glass bottles and 120,000 375-milliliter cans per hour,
* for Castlemaine Perkins in Milton, Brisbane, one pasteurizer for 66,000 375-milliliter cans per hour.
HIJOS DE RIVERA, LA CORUNA
TRADITION AND TECHNOLOGY
Hijos de Rivera in La Coruña, Spain, a company with more
than 100 years of tradition, has ordered the latest equipment for a beer line from KHS, which will process 60,000
0.2 and 0.33-liter non-refillable and refillable glass bottles per hour. The company Aguas de Cabreiroa, which
is also part of the group, took delivery of a wide range
of equipment from KHS back in 2006.
COCA-COLA FEMSA GROUP, MEXICO
54,000-BPH NON-REFILLABLE
PET BOTTLING LINE
Propimex Orizaba Operational Unit, part of the Coca-Cola
Femsa Group in the Mexican city of Orizaba (in the state
of Veracruz), continues to place its trust in KHS quality,
and has now ordered a comprehensive PET non-refillable
line for 54,000 bottles per hour (600 milliliters) or 27,000
2.0-liter bottles. The newly designed Innofill DRV VF 128
filler is the largest in this region. The Femsa Group has
decided to incorporate one of its Coca-Cola soft drinks
lines into a brewery for the first time.
08*09
NEW BOTTLING LINE FOR THE ’KING OF BEERS’
KÖNIG-BRAUEREI INVESTS IN THE LATEST KHS
FILLING AND PACKAGING TECHNOLOGY
With its top products König Pilsener, König Pilsener Non-Alcoholic
and König Pilsener Lemon, the König-Brauerei in Duisburg is one
of the largest and most successful premium breweries in Germany.
König Pilsener is today a byword for the top Pilsener. Such a reputation has not come about by chance. The highest expectations
have always been placed on product quality at König, and on the
manufacturing processes and technical equipment used to produce it.
It is therefore no wonder that KHS was awarded the contract when the decision concerning investment in new system
technology was made. Guido Christiani, Production/Engineering
Director of König-Brauerei: “With KHS, we are relying on a partner of long standing, who enjoys our full confidence and whose
technical solutions impress us in every respect.”
The innovative KHS plant equipment ordered is a high-performance system. The refillable line is designed for a nominal
output of 55,000 bottles per hour. The 0.33-liter Steinie bottles
and 0.33 and 0.5-liter longneck bottles are filled with the premium products of the König-Brauerei. The line is designed to be
extremely flexible and is already well equipped for all possible
future ’filling options’ even today.
The KHS scope of supply starts with the Innopack PPZ
decrater – a two-axis machine of the latest generation, which has
outstanding accessibility and is characterized by simple operating procedures. This type of machine is equally suitable for use
as a crater as well as a decrater. For this reason, the König-Brauerei
decided to opt for two Innopack PPZ machines.
A KHS Innoclean EM single-end bottle washer is used for
washing the bottles. This also has numerous special features. A
pre-caustic bath with additional label discharge and three preheating zones means low contamination of the main caustic bath
and the associated specific saving of chemicals.
Another important factor: by integrating Triple-i-Drive
equipment into the bottle washer, it is possible to process widely
different bottle shapes, sizes, and materials with ultra-short
changeover times.
The heart of the KHS line is the Innofill DRS-ZMS filling
system. Here, the fill level is accurately determined by means of
fill level probes. The pressurizing and filling process is preceded
by triple pre-evacuation and double CO2 purging. This ensures
low-oxygen filling and specific CO2 savings. Other advantages of
Confidence in KHS filling and packaging technology for the ’King of Beers’: LutzPeter Sieckel, Bottling/Logistics Manager and Guido Christiani, Production/Engineering Director of the König-Brauerei, at the contract award meeting with Günter Unkrig, Director, Central European Business Area, and Wolfgang Augel,
Sales, Germany, KHS AG (left to right).
the filling system include short changeover times for product and
bottle changes, high availability due to the central fill level adjustment, the speed and standstill-independent process, and the adaptation of the filler output to the particular line capacity. Christiani is highly impressed with “a filling system, which ensures the
outstanding quality of our premium products, particularly due to
be extremely low-oxygen filling process.”
Another highlight of the innovative KHS plant equipment is the ReDiS (Remote Diagnostic Service) remote mainte-
nance system. ReDiS enables machines to be analyzed directly
from KHS headquarters. All machine control systems can be
accessed directly on request. This ensures that rapid assistance
is possible. It is also possible to carry out reprogramming ’from
a remote site’. “With the KHS equipment we have chosen, we have
a solution, which leaves nothing to be desired, and which satisfies our high quality expectations in all respects,” Guido Christiani sums it up.
DIAGEO OPERATIONS ITALY
KULMBACHER BRAUEREI, KULMBACH
PERFECT WINE FILLER
50,000 BPH LINE FOR KULMBACHER
A complete filler-rinser-capper block complete with associated process equipment (filtration, wine heater, CIP)
for bottling wine is to be delivered to picturesque Santa
Vittoria d’Alba for Diageo Operations Italy. The filler
works using the Trinox process and can be flexibly used
for still and carbonated beverages. In all, exactly what
Diageo, as one of the world’s leading companies for premium beverages, could want.
The renowned Kulmbacher Brauerei in the Franconian city of Kulmbach is
taking delivery of a complete 50,000 per hour beer-bottling line for refillable
glass bottles. The company places special emphasis on the economic use of
primary energy. The system is full of innovations in washing machine technology and has a high degree of automation (automatic format changing in the
dry area, automatic probe adjustment at the filler). Kulmbacher places great
importance on microbiological safety (microbiological front table at the filler,
microbiologically optimized conveyors). Maximum flexibility is required. The
combined Kulmbacher breweries EKU, Reichelbräu, Mönchshof, and Kulmbacher
produce around 1.4 million hectoliters of beer annually.
COCA-COLA ENTREPRISE,
BERGUES, FRANCE
TOP PACKAGING TECHNOLOGY
As with the existing lines, Coca-Cola Entreprise in the
French town of Bergues (Socx) is placing its trust in futureoriented packaging technology from KHS. The company
is taking delivery of a complete dry section with a Kisters
SP 60V shrink packer and a Kisters TSP 60V tray shrink
packer as well as palletizers, conveyors, and a bottle conveyor designed for an output of 36,000 0.5-liter PET bottles per hour. Included are a leaflet inserter and the processing of up to three lanes for 4-bottle, 6-bottle, and
12-bottle packs; the option of processing loose products
in film, with tray, pad or multipacks; robot grouping station; layer pattern generator sets up independent layer
patterns; retrofitting for half-pallets possible at any time.
The result is maximum flexibility so that every market
opportunity can be taken in future.
BRAUEREI HIRT, MICHELDORF, AUSTRIA
KHS KEG TECHNOLOGY IMPRESSES
The Brauerei Hirt in Micheldorf, Austria is replacing the
old KHS keg system, which has been serving well for
many decades, with a new KHS keg racking line that
processes 240 kegs per hour. The main components:
Innokeg Till TRANSOMAT 5/1 racker, Innokeg Till AK-3
exterior washer, 180-degree turner, capper, and shrinker
as well as the necessary conveyors. The latest features
such as Clean Design, the patented volumetric filling
technology DFC and IDM are of course included. Overall, the Brauerei Hirt will be able to make considerable
savings on consumables in the future and build on high
system efficiency.
PIVARA TUZLA, BOSNIA AND HERZEGOVINA
BEER AND MINERAL WATER LINE
Satisfied customers are the best recommendation. KHS is installing a complete bottling line with a nominal capacity of 36,000 0.5-liter bottles per hour
at Pivara Tuzla in Tuzla, Bosnia and Herzegovina. The line will process refillable and non-refillable bottles and will optionally bottle beer or mineral water.
LA ZARAGOZANA, SARAGOSSA
LINE STARTS FOR EXPO
As part of its investment offensive, the old established brewing company La
Zaragozana S.A. in Saragossa, Spain, has now ordered a rinser-filler-capper block
as well as a pasteurizer to be inaugurated at the same time as Expo 2008, which
will be taking place in Saragossa. The output of the line will be 60,000 0.2 and
0.25-liter glass bottles per hour. In July, La Zaragozana ordered an Innopack
Kisters WP 60 wrap-around packer and an Innopack Kisters TSP 50 tray shrink
packer. Back in January, the company had decided in favor of an Innokeg Till
TRANSOMAT from KHS, which has been running highly satisfactorily since June.
10*11
COCA-COLA ARCA GROUP, MEXICO
45,000-BPH NON-REFILLABLE PET LINE
LAO ASIA PACIFIC / LAO BREWERY
KHS IN LAOS: ALL FROM ONE SOURCE
As in neighboring Vietnam, beer in the People’s Republic of Laos has
been on the advance for years. KHS is one of the pioneers in the
country when it comes to the installation of production systems for
the comparatively new brew. The perceived motto: In Laos, beerbottling lines are ordered from KHS.
Lao Asia Pacific: On board with partner Heineken. Lao
Asia Pacific Breweries with its production facilities in Vientiane is a
100-percent subsidiary of the Asia Pacific Brewery in Singapore. The
Heineken supply chain handled all of the engineering for the new
brewery. KHS is supplying a complete bottling line for refillable
glass bottles.
Lao Brewery: New line for new brewery. The Lao Brewery Company Ltd. (headquarters in Vientiane) is building a brand
new brewery in Pakse province as part of a so-called greenfield project. Ninety-eight percent of the output of the company, which was
founded in 1973, is produced for the domestic market. The logo
depicts a panther. Lao Brewery sells around 60 million liters of its
main product, Beer Lao, each year. The company obtains hops and
yeast from Germany – like the bottling lines. KHS has already supplied the fourth bottling line to the management’s complete satisfaction.
Coca-Cola Arca is the second-largest Coca-Cola franchise group in
Mexico. It incorporates three Coca-Cola companies in Mexico’s
northern region: Argos in Ciudad Juarez, Procor in Monterrey, and
Arma in Saltillo. This new strongly growing group operates with
around 35 lines throughout the country and has more than 40 KHS
fillers in operation. The Embotelladora Pitic plant in Hermosillo in
the state of Sinaloa is now investing in a KHS non-refillable PET
line designed for 45,000 bottles per hour (600 milliliters) or 23,000
bottles per hour for 2.0 liters. This is the first complete nonrefillable PET line for the Arca Group.
PRIMO SCHINCARIOL / REMIL, BRAZIL
EFFICIENCY CONSULTING
One of the leading German brewing companies, Warsteiner Brauerei
Haus Cramer in Warstein, has again decided in favor of KHS filling
technology: a complete refillable glass line with an output of 55,000
0.33-liter bottles per hour. The new line equipped with the latest
in filling technology works with a high degree of automation and its
design is comparable with that of the already existing KHS line.
The large Brazilian company Remil (Refrigerantes Minas Gerais)
and Primo Schincariol (Schincariol Industria de Cervejas e Refrigerantes) have independently tasked KHS Brazil to check out – and
if necessary – improve the efficiency of their systems and operating facilities. The KHS experts will check the operation of the lines
or determine and evaluate the speed of the machines in accordance
with an exactly defined project plan. Possible faults, operator
response times, setting up of machines and products, mistakes in
the use of materials and programs and the number of rejected bottles will also be recorded. Finally, the KHS specialists will determine the availability index, the quality and efficiency, and the performance of the lines (O. E. E. value). The company will then be
given an improvement plan with particulars of achievable increases
in production. By implementing the proposals, the companies will
be operating their systems in an optimum technological and economic manner with increased profitability. Primo Schincariol employs
a workforce of 6,000 employees in South America’s largest industrial park, and bottles primarily mineral water, beer, and carbonated beverages. Remil is a manufacturer and sales outlet for CocaCola and with 3,200 employees produces nearly 46 million liters of
beverages every month.
KISII BOTTLERS, KENYA
ECKES-GRANINI GERMANY, HENNEF-BRÖL
PARTNERS FOR DECADES
ACF … FOR THE THIRD TIME
Kisii Bottlers Ltd. in Kisii, Kenya has been relying on quality and service made by KHS for several decades. The successful company has
most recently ordered a refillable glass line with a capacity of 36,000
bottles per hour (0.2, 0.3, and 0.5 liters). KHS is also supplying refrigeration equipment, the syrup room, and water treatment.
Eckes-Granini, one of the leading fruit juice producers in Europe,
is investing in a KHS non-refillable PET ACF line, which will fill
24,000 1.0-liter bottles per hour. This is already the second ACF
line from KHS in the Hennef-Bröl plant near Bonn and the third
ACF line for Eckes-Granini Germany.
WARSTEINER BRAUEREI HAUS CRAMER, WARSTEIN
55,000 BPH LINE FOR WARSTEINER
INNOCOLL FOR
ALL LABELS
INNOCOLL FOR
WRAP-AROUND AND
TRAY PACKS
dossier °
12*13
The right adhesive for every application: The KHS Innocoll hot melt range now also holds wrap-around
and tray packs firmly together. In practice, this means that it is no longer necessary to change to
other types of adhesive. No blocking of nozzles. The operating crew is not exposed to annoying odors.
No more uncontrolled splashing. An all-round, worry-free package from KHS – all from one source.
The
Innocoll: New KHS hot melt for wrap-around and tray packs
SUPER
ADHESIVE
The devil is in the detail. Anyone in the
beverage, food and non-food industry who
has ever had anything to do with packaging or labels knows this only too well. For
here, the smallest inaccuracies or non-optimized processes can have a noticeable effect
on the efficiency of systems and machines,
and also on the successful sale. With a
label, tenths of a millimeter are decisive,
and a poorly glued tray usually stays on the
shelf – if it has not already long since fallen
apart.
For KHS, turnkey supplier to the filling and packaging industry and one of the
technological leaders, only an integrated
approach to technical solutions counts. From
now on, KHS will therefore also be providing a universal adhesive for tray and wraparound packaging machines – based on
extensive experience with the Innocoll range
of adhesives in labeling technology. Basically, the machine, adhesive and material
must be in perfect harmony. Only in this
way can the set objective be achieved – a
perfect result and the maximum machine
efficiency with long service life.
While, along with a wide range of
cold adhesives (based on casein, starch, or
synthetic polymers), KHS also offers EVA
(ethylene vinyl acetate) and rubber-based
hot melts for labeling technology, only hot
melt is normally used for tray and wraparound packaging. In practice, it works like
this: KHS recommends the optimum adhesive for the container or label material from
the Innocoll range, which covers all conceivable requirements. The interaction of
all components is checked in the KHS plant
before the technical solution is delivered.
Beverage, food, and non-food companies
are ultimately provided with the complete
solution, which is ideal for them, and thus
a welcome all-round worry-free package.
2
INNOCOLL FOR HOT REGIONS
For regions in which particularly high temperatures
prevail, KHS has developed special types of glue for
tray and wrap-around packs – with minor modification to the climatic conditions. Depending on
the application, combining KHS hot melt and KHS
cold adhesives is absolutely feasible in order to
enable reliable, durable adhesion even when subjected to the effects of constant extreme heat.
+ DELIBERATELY SIMPLE
Based on the results of comprehensive
research, Innocoll works in a markedly simple fashion for tray and wrap-around packaging. There are only two types of hot melt:
* Innocoll HMP 2112 for tray packs, and
* Innocoll HMP 2113 for wrap-around
packaging.
As is usual in the case of hot glues, the two
types consist mainly of resins, waxes, and
EVAs (ethylene vinyl acetate). KHS uses
only high-quality raw materials. Only these
can ensure the broad spectrum of use of
KHS hot melts.
To ensure the perfect application
of glue, KHS accurately specifies certain
parameters for each case, such as the temperature of the glue and the pressure with
which the glue must be applied to the cardboard material. These values are always
provided on an engraved label directly on
the machine housing.
Temperature. The temperature
the glue must have in the tank, hose, and
nozzle is defined. The tank, as well as the
hose and nozzle, are equipped with independently working heating systems. So
that the glue cannot boil on the way to the
nozzle, the prescribed glue temperature in
the tank is in each case somewhat lower
2
than in the hose, and this in turn is lower
than in the nozzle head. The glue therefore heats up slowly. By the time it is applied
to the cardboard, it has reached the perfect application temperature.
Pressure. KHS specifies the precise pressure at which the glue should be
applied to each type of cardboard in order
to achieve the desired results.
+ NO MORE CHANGEOVERS
REQUIRED
Changeover to new types of hot melt when
you switch packaging materials is no longer
necessary. No time is lost for setup and
INNOCOLL FOR ALL LABELS
Labels should fit like a tailored suit – exactly. Accuracies of fractions of a millimeter are
involved, and here KHS has decades of experience. Within the innovative range of Innocoll
adhesives, KHS provides widely differing adhesive solutions especially for labeling machines
– whether with cold glue or hot melt, for glass or PET bottles, cans or for special tasks such
as the application of tax revenue stamps. Here, as with tray and wrap-around packs, the
decisive factor is that comprehensive know-how is used to accurately match all existing
parameters. No more but also no less.
cleaning. Added to this: the risk of confusing different types of glue is eliminated
right from the start.
+ NO CLOGGING OF
NOZZLES
+ NO UNCONTROLLED
SPLASHING
Also of the highest significance for perfect
glue application is the nozzle head. A problem encountered in practice is the use of
different nozzle heads where the glue application is often no longer accurately controlled when the heads are changed (imprecise gluing, contamination). And, in the
case of nozzle systems with capillary tubes
that are commonly available on the market, there is also the risk that the nozzle
becomes clogged due to adhesive or dirt
particles (replacement, machine shutdown).
KHS has therefore jointly developed
a new type of nozzle head, which in principle works in a similar way to a combustion engine. A pneumatically controlled
valve ensures the application of the specified quantity of glue, and also has a selfcleaning function. Clogged nozzles are a
thing of the past.
dossier ° Innocoll: New KHS hot melt adhesive for wrap-around and tray packs
14*15
Left Calculated simplicity: For KHS tray and wrap-around packaging only two types of hot melt are needed: Innocoll HMP 2112
for tray packs and Innocoll HMP 2113 for wrap-around packs. Right Patchwork: Together with a renowned hot melt unit
manufacturer, KHS has designed new hot melt application heads and modules, which, like the nozzle-needle set, are selfcleaning and can no longer become clogged.
*
details of carton design, such as whether
grip openings are required, in order to
increase the ease with which the pack
can be carried. More glue points are
then required for heavy products.
The general rule: each individual case
is always examined. What’s more, KHS
will hold discussions with the carton
manufacturer at the same time if required.
+ EXISTING SYSTEMS CAN
BE CONVERTED
+ HIGHER MACHINE
AVAILABILITY
Customers who decide on the ’KHS allaround worry-free package’ for tray packers and wrap-around packers get a standardized solution from KHS that has been
thought out to the last possible detail. In
this way, KHS ensures higher machine availability. Additional advantages are lower
adhesive consumption, stable glue points,
high-quality raw materials, accurately specified pressure and temperature, and a particularly low tendency to boiling.
+ OPERATING CREW NO
LONGER EXPOSED TO
STRONG ODORS
Both types of hot melt also offer ecological
advantages. The use of high-quality raw
materials ensures that emissions are kept to
a minimum. Strong glue odors are no longer
a problem for the operating personnel.
+ NO CHARRING OF
ADHESIVE
In order to reduce the continuous refilling
of the hot melt reservoirs, KHS offers an
option for automatic refilling. The basic
principle is that hot melt granules are fed
from a magazine directly into the hot melt
tank under vacuum in pre-specified amounts
and at the defined time. Another advantage of this method is that it can no longer
happen that too much cold granulate can
cause a machine stoppage resulting from
removal of heat from the already liquid
adhesive. Conversely, there is no more
charring of the glue caused by adding an
insufficient amount of granulate. Another
thing that must not be underestimated is
that, because the hot melt reservoir does
not have to be opened, the melted glue is
almost never exposed to oxygen. There are
no longer any negative consequences of
oxidation such as increased charring.
Existing KHS tray and wrap-around packers can be converted to the new adhesives
without difficulty. For example, the hot
melt pump and nozzle heads must be replaced
and special filter solutions fitted.
In brief: Since KHS consistently
adheres to the policy of all from one source,
there is no more so-called 'finger pointing'
between machine manufacturer, glue manufacturer and glue application unit manufacturer and the carton supplier. This drives
the devil out of the detail.
Werner Oster, Technical Sales, Packaging
Technology Division, KHS AG, Kleve
Joachim Brzoska, Sales Manager Adhesives,
KHS AG, Dortmund
fi
INFOBOX
• WEBSITE www.khs.com
+ ALL DATA DEFINED
At a very early stage, KHS provides
accurate technical specifications, which
have been agreed with the company. For
example
where glue is to be applied and there*
fore the cardboard must not be coated,
* how folding and bending forces exactly
define the different types of
cardboard, or
• CONTACT
Werner Oster, Technical Sales
Packaging Technology Division, KHS AG, Kleve
Tel:
+49 (2821) 503–152
E-mail: werner.oster@khs.com
Joachim Brzoska, Sales Manager Adhesives,
KHS AG, Dortmund
Tel:
+49 (231) 569–1946
E-mail: joachim.brzoska@khs.com
“Here in China, we like to
rely on German know-how”
Interview with XIAO Derun, Chairman of the China Brewing Association
With more than 1.3 billion inhabitants, China is the most populous land in the world, with the largest area of any country in
East Asia and the fourth largest on Earth. As an economic region,
China is gaining ever more significance. In 2006, the country
achieved a growth rate of 10.7 percent, rising with its gross
domestic product of about €2 trillion to the rank of the fourth
largest economic power in the world. China is one of the internationally most dynamic economic regions. While the gross
domestic product is currently around €1,500 per capita, experts
are anticipating a rise to €2,250 by 2010. If we look at the data
and facts about the Chinese market, it’s very clear that this will
result in a solid increase in consumption in a number of areas –
including the beer market. Since 2002, China is the world’s
largest producer of beer. In the meantime, the country has about
a 20 percent share of world beer consumption. According to XIAO
Derun, Chairman of the China Brewing Association, the Chinese
beer market will continue to be extremely interesting in the
future, with plenty of growth potential. KHS journal, talks with
XIAO Derun, an industry expert ’par excellence’.
KHS JOURNAL: Mr. XIAO, you are the Chairman of the China
Brewing Association. Please give us an overview of the main
responsibilities of that organization.
XIAO DERUN: The tasks of the China Brewing Association are
simple to summarize, because basically, we’re responsible for
everything the Chinese brewing industry needs and finds interesting. Whether compiling statistics from the brewing industry,
organizing further education events, consulting with the government, defining quality standards, providing know-how on
technical questions, or even marketing strategies – the China
Brewing Association, as a part of the China Alcoholic Drinks Association, is the right contact. The China Brewing Association was
established in the market in 1990. It was split off from the Ministry for Light Industry as an independent association. Within
China, the China Brewing Association is still the only authorized
association of breweries today. About 98 percent of all breweries are members. That means that about 500 breweries belong
to our organization. Membership is also open to the sub-supplier industry, by the way. We have numerous member companies such as the raw materials, brewing technology, and packaging industries.
As one of the tasks of the China Brewing Association, you
mentioned consulting with the government. Of course, the
Chinese brewery industry was a government domain for a
long time. How strong is the influence of the state today?
The state’s share has decreased significantly. Only 1.7 percent of all breweries are still 100 percent state-owned. Today,
the brewing industry as a whole is 44.4 percent privatized, and
that percentage will continue to grow. A total of 33.9 percent
of breweries are traded on the market as public corporations.
°
*
dialog+opinion °
16*17
XIAO Derun, Chairman of the China Brewing Association is an industry expert ’par excellence’. Before he assumed the business management of the China
Brewing Association in 1990, XIAO Derun was entrusted with management of the brewing industry within the Chinese Ministry for Light Industry.
And it is also true that many foreign investors are involved in
the Chinese brewing industry. We say that about 20 percent of
the Chinese brewing industry is in foreign hands. Primarily in
the context of joint ventures with Chinese breweries.
How do you see the strong international entry into the
Chinese brewing industry, and what particular details, in
your opinion, do foreign companies need to watch if they
want their activities on the Chinese beer market to be successful?
We see the entry of international companies extremely positively, and we consider it very important for the continued development of the Chinese beer industry. However, experience tells
us that foreign companies who want to be successful on the Chinese market have to pay attention to a few important things. In
the early 90s, there was a whole wave of investment on the Chinese beer market. International brewing groups came, built
breweries, produced international beer brands there, and tried
to bring them to market at a high price. At the same time, these
companies established a management system that didn’t match
the Chinese management system. That didn’t work well, and
many international companies left China again in a very short
time. Many of these international companies tried again a few
years later – with the goal of achieving a positive market entry
in China this time, and they were successful with a completely
different strategy. I’d like to take this opportunity to note what
in my opinion are the significant key points for the success of
foreign companies in the Chinese brewing industry. First, it is
always a good idea to strive for a joint venture with a Chinese
brewery. Establishment of a Chinese management system and
the continuation of existing Chinese beer brands previously pro-
°
*
duced at the brewery location are both significant. Only when
the local brands are profitable and the joint venture is stable
should international brands be integrated into the product portfolio. I also recommend adhering to this order, because consumers in China are very much focused on the Chinese beer flavor. They also find it very important for a company to be managed according to Chinese principles.
About data and facts concerning the Chinese beer market:
How do sales and per capita consumption behave in China
over the years, and what predictions can you make?
If we look closely at the Chinese beer industry, it is clear that
we have to distinguish between ’before 2004’ and ’after 2004’.
Before 2004, we talked about growth rates of between 5 and 7
percent annually. After 2004, we see a continual yearly plus of
more than 10 percent. In 2006, there was a particularly strong
growth in beer consumption, with a jump of 14 percent. Per
capita consumption rose to 27.5 liters. On average, every Chinese thus consumes more beer than the world average of 26 liters
of beer per year. By 2010, we expect the positive tendency of
the Chinese beer market to continue, with more yearly growth
rates around 10 percent. It may be that growth will flatten out
a little after 2010. Total beer sales in China today are 350 mil-
°
*
20 percent of the Chinese
brewing industry is in foreign hands. Primarily in the context
“We estimate that about
of joint ventures with Chinese breweries.”
lion hectoliters per year. For 2010, we are predicting around 450
million hectoliters, and a per capita consumption of about 35
liters.
You speak of ’before 2004’ and ’after 2004’. Why did beer
sales take off in 2004 so particularly?
The biggest economic centers in China lie mostly in the coastal
regions. Before 2004, breweries were mostly built there, and
beer was distributed almost exclusively on those regions. Since
2004, investments of domestic breweries – often with the support of overseas partners – have taken place specifically in other
Chinese regions. Preferably in the southeast of China, but also
in more rural areas in the interior. The expansion of additional
distribution regions allowed and is allowing beer consumption
in China to rise a little, naturally. In my opinion, in many areas
of China there is still a lot of ’beer potential’. The following fact
additionally speaks for continued growth in beer sales. Of the
1.3 billion inhabitants of China, 800 million are farmers, for
whom the daily consumption of beer is unthinkable, if only for
financial reasons. With continued growth in income, beer will
also be more affordable in the future for the low-income target
group.
°
*
Regarding target groups. How are the target groups for
beer in China defined? Is beer primarily a drink for young
adults here, or more for an older segment of the population?
As far as age is concerned, we consider the main target group
for beer to be the group of 20- to 50-year-olds. The beer consumption of 50- to 60-year-olds is relatively low, but they still
°
*
drink beer occasionally due to its low alcohol content and high
nutritional value.
Internationally, beer is often communicated as an extremely
healthy product. Does that kind of communication also
exist in the Chinese market?
The China Brewing Association has presented beer as a healthy
product for years. The population of China accepts that communication well.
°
*
a popular drink among women in China?
° IsDueChina
to the communication of beer as a healthy drink, more
*
and more women enjoy a glass of beer.
What styles of beer are the most popular in China, and at
what price is beer available on the Chinese market?
Chinese love their lager. That’s because they prefer the light
beer taste. Eighty percent of all beer sales today are lager beer.
The remaining twenty percent include all imaginable beer styles.
Whether Pils, wheat beer, or non-alcoholic – every style is available in the Chinese beer market. While local beers are primarily
in the medium price segment, premium beers including most
international beer brands as well as the best-known local beers,
are in the high price segment. The average price in China for the
local 600-milliliter bottle of lager is around 2 RMB. That’s about
€ 0.2. For premium beers, you can count on four or five times
that price.
°
*
Are international premium beer brands mostly produced in
China today, or are many of them imported?
Only a very small portion of international beer brands is
imported. All in all, 0.27 million hectoliters. Anyone who wants
success in the Chinese market – and we see this again and again
– has to be present locally.
°
*
beer sales of around 450 million hectoliters in the Chinese market, and a per capita consump-
“For 2010, we are predicting
tion of about 35 liters.”
°
What about exports of Chinese beer to international markets?
dialog+opinion ° Interview with XIAO Derun, Chairman of the China Brewing Association
18*19
KHS and GLM2, we see a clear win-win
“In the joint venture of
situation for everyone involved.”
Here, too, we’re talking about a relatively low number of hectoliters, a total of 1.7 million. That’s because the international
market isn’t yet ready to pay high prices for beer from China. If
that attitude changes, export numbers might rise. However –
and I want to make this perfectly clear – for breweries in China,
the focus is always going to be on China. After all, what can be
better than to be part of the beer market, which is the fastest
growing in the world, both today and in the future?
founded with GLM2, a large Chinese manufacturer of filling
and packaging technology?
We are extremely happy to see this joint venture. KHS is acting exactly according to market requirements in this case. In
this joint venture, we see a clear win-win situation. In addition
to KHS and GLM2, the Chinese market of the beer industry in particular as well as the Chinese market for the beverage industry
in general will profit greatly.
°
Is the Chinese beer industry still looking beyond the borders in terms of engineering and technology?
Historically, too, we have always looked to the German beer
market. Even in the early 80s, when the Chinese brewing industry was still part of the Ministry for Light Industry, many young
people were sent to the best-known German brewing schools to
take up their studies there. Today, it is these people who hold
key positions in the Chinese brewing industry, and they characterize the industry. So the brewing process in many Chinese
breweries is based on the German. By the way, there is a tradition now very popular with the people of China that comes from
Germany. That is the tradition of celebrating beer festivals. In
many large cities of China today, there are well-visited beer festivals modeled after the famous Oktoberfest in Munich. And as
far as technical solutions are concerned, we also like to rely on
German know-how. In our opinion, many outstanding technical solutions come from Germany.
°
*
2
*
°
In that context, how do you see the recently established
joint venture that KHS, as an international manufacturer of
filling and packaging technology with German roots, has
*
Mr. XIAO, thank you very much for this interview.
THE TOP 10 BREWERY GROUPS IN CHINA
Brewery groups
1
2
3
4
5
6
7
8
9
0
Production in millions
of hectoliters in 2006
China Resources Snow Breweries
52.9
Tsingtao Brewery Group
45.0
Beijing Yanjing Beer Group
35.3
Chongqing Brewery Group
17.5
King Star Brewery Group
16.6
Harbin Brewery Group
15.2
Zhujiang Brewery Group
13.3
Inbev Brewery Group
10.1
Kingway Brewery Group
6.4
Suntory Brewery Group
6.3
Left Dating back to the 13th century: Brewing tradition in Budweis. Right Electronic bottle turret control: Aligns labels accurately with the bottle
embossing using the latest camera technology. Bottom right Trademarks: Registrations in 101 countries.
Old-established Budweiser Budvar brewery invests in the future
Time for
1
Quality
THE TASK nstallation einer
Installation of trend-setting labeling
equipment for the new Pardal beer brand
as the third step of a comprehensive
modernization program.iblen Abnie für
das schoKräuterlikör.
2
THE SOLUTION
Two KHS Innoket SE 2080 labeling
machines
• each equipped with two cold glue
labeling stations
• each of which processes 48,000
bottles per hour
•of various shapes and sizes
The name Budweiser sends passionate beer
drinkers around the world into raptures.
This is no passing fad. For the brewery in
Budweis is continuing the much-vaunted
Czech beer tradition with increasing sales.
Since it was founded as Tschechische Brau
AG in 1895, the special brewing process of
today’s Budweiser Budvar Brewery has been
delighting the international community of
fans.
The recipe for success: Homegrown
ingredients such as Saazer hops, Moravian
malt, and water from the brewery’s own artesian wells, over 300 meters deep, give the
beer its unique taste. An unusually long
storage time makes the drinking pleasure
perfect. Lager matures for 90 days and strong
ale for as much as 200 days. At Budweiser
Budvar, they take plenty of time for quality.
Comment by Master Brewer Josef Tolar: “Our
consumers deserve to get only the best quality.”
But high-quality ingredients and
the particularly careful brewing process are
not the only quality features, which impress
the restaurant trade, retailers, and consumers. The Czech brewery also takes great
care to put the beer into the appropriate
container in the best possible way and to
present it as attractively as possible. This
has always been highly successful since the
start of the collaboration with KHS. In the
meantime, Budweiser Budvar has implemented three modernization steps together
with KHS.
STEP 1: BOTTLE WASHERS
It began in 2005 with the installation of two
Innoclean EE bottle washing machines – one
for each glass line. Both machines are
equipped with triple pre-heating and integral pre-washing. They also have numerous
features, which ensure the highest level of
user-friendliness and maximum availability.
Integral Triple-i-Drive technology and the
patented energy-saving bottle carrier provide additional advantages, which have a
positive effect on ecology and economy. The
old washing machinery was replaced by the
new machines in only four days. No wonder that Master Brewer Tolar was “highly satisfied from the very start” with the innovative KHS bottle washing equipment.
STEP 2: PASTEURIZER CONTROL
The second modernization step, the conversion of existing KHS pasteurizing equipment,
was completed in 2006. As well as chang-
task+solution °
In spite of stagnating beer consumption on the domestic market, the sales
figures of the Czech Brewery, Budweiser Budvar, are increasing apace –
partly due to the newly created draft beer, Pardal. KHS technology provides the necessary marginal conditions.
20*21
2
THUMBNAIL PORTRAIT: BUDWEISER BUDVAR
* Founded in 1895 as Tschechische Brau AG
* Name changed to Budweiser Budvar Brewery
in 1967
* Best-known brands: Budweiser, Budvar,
Budweiser Budvar, Budejovicky Budvar,
Bud, Czechvar
* Total output 2006: 1.152 million hectoliters, of which the export share was around
50%
* Third largest export brewery in the Czech
Republic
Output
2006 compared with 2005: + 5.8%
*
(with stagnating overall market in the
Czech Republic)
* Distribution of sales: 62% lager, 32% draft
ing to the most up-to-date control equipment, this mainly involved the integration
of the KHS PU control. This provides maximum microbiological safety with minimum
effect on the product taste. With the KHS
control system, the pasteurizer is divided
into different zones. Due to the particularly
fine grid structure, the pasteurization values for each individual bottle can be accurately reproduced at all times. The system
stores the data and files them appropriately.
The PUs of all bottles can therefore always
be retrieved later. Each pasteurizer is equipped
with a PC with visualization. This undertakes the complex mathematical calculations.
STEP 3: LABELING TECHNOLOGY
Modernization step number three, the installation of two KHS Innoket SE 2080 labeling
machines, was carried out a few months ago.
The investment was made necessary by the
newly introduced draft beer Pardal (Czech
for panther) in March 2007.
This brand of beer differs from the
previous Budweiser-Budvar brands in four
ways: 1. It has an independent name. 2.
Pardal has a completely new taste. 3. The
beer is intended to become established in
the medium rather than the high price segment. 4. Pardal is aimed at younger men
and therefore at a target group that has not
been developed previously. Pardal came
beer, 6% non-alcoholic beer and strong ale
* Proportion of total sales: Glass bottles 48%,
kegs 48% (KHS has supplied two turnkey
lines), cans and tanks 4%
* Main export countries: Germany (200,000
hl), United Kingdom (100,000 hl), Slovakia,
Austria, Italy, Russia, France, Spain
* Export countries worldwide: 50
* 380 registrations of trademarks in 101
countries
* Recipient of numerous national and international awards (currently: ’Beer of the Year
2007’ in the Czech Republic, incorporation
in the prestigious CoolBrands list in United
Kingdom)
into being after close discussion with potential customers. The brewery first created a
beer with a somewhat bitter taste and then
let it be tried in numerous inns and restaurants. Budweiser Budvar developed the
product in accordance with the testers’ wishes
until they were totally satisfied. The name
also came about as a result of teamwork with
the people. The Czechs were called upon to
submit suggestions for names. Ultimately,
Czech beer fans are the supporting pillar of
the current brand campaign and genuinely
recommend Pardal on billboards and advertising columns.
The new beer has become a top seller
at lightning speed. Budweiser Budvar will
easily achieve and presumably even exceed
the 23,000 hectoliters planned for 2007.
The unique product dressing with innovative KHS labeling equipment also contributes
to the success. Its three outstanding characteristics are flexibility, precision, and
robustness.
Flexibility for labels and bottles
The new labeling machine generation is
highly flexible due to its modular design.
The simple basic arrangement consists of
a table structure and the central labeling
carousel, which can be equipped with a
wide variety of labeling stations. Budweiser
Budvar decided upon two cold glue labeling stations and camera-based alignment
modules. While the first station applies
shoulder and neck labels, the second station carries out the back labeling. This
enables the company to apply hot melt,
adhesive-pressure, or roll-feed labels on
either of the two Innoket SE 2080 machines
as labeling needs change. If there should
be a need to implement any of the labeling processes listed, the only thing necessary would be an investment in additional
corresponding labeling stations. As far as
conversion to new labeling stations is concerned, on the Innoket SE 2080 all that is
needed is to simply dock and undock the
task+solution ° The brewery of tradition, Budweiser Budvar, invests in the future
22*23
Left Third modernization step: Two new KHS Innoket SE 2080 labeling machines... Bottom right ... and a new
Innopack Kisters WP 60 wrap-around packer. Bottom left Josef Tolar, Master Brewer Budweiser Budvar, “KHS
labeling technology fulfills all of our requirements for precision, flexibility, user-friendliness, and robustness.
Our appearance at the point of sale is outstanding.”
stations. When labeling stations are changed,
all stations can be automatically synchronized with one another by software and
computer. Naturally, the machines are able
to process widely differing shapes and sizes
of bottle (currently 0.33 and 0.5-liter glass
bottles).
Precision for embossed bottles
With regard to labeling, the most important
thing is to align the embossed glass bottles
accurately for applying the front and back
labels. A particular challenge for KHS was
that the Budweiser Budvar embossing contains the letter B four times. Shoulder and
neck labels must be oriented to this embossing so that they are centered between the four
Bs and, at the same time, along the same line.
The VarioDrive electronic bottle turret control system in conjunction with the
latest camera technology makes it possible
to achieve this accurate positioning. With
the VarioDrive, the bottle turret, motor, and
electronic equipment form a single unit and
communicate with one another. Individual
bottle rotation in the labeling carousel is
geared entirely to the bottle format and style
of dressing. When the bottles are positioned
on the bottle turret, they are rotated at high
speed. Three consecutive camera systems,
which are coupled with a lighting unit, enable
both coarse and fine alignment to be carried out in accordance with analyzed bottle
data. A computer algorithm evaluates dif-
ferences in contrast, and compares the actual
and required state. A bus system communicates individual correction steps directly
to each individual VarioDrive.
Flexible adaptation of the program
and associated extensions for new container
shapes and dressings are possible at any
time. In this way, the labeling machines
can be changed over to accommodate new
trends and market requirements in the shortest possible time. Stored labeling programs
can be retrieved at the push of a button.
However, KHS had yet another problem to solve. Some of the Czech brewery’s
beers require accurate mouth and crown cork
labeling with an aluminum label. The KHS
solution: The optimum brushing of the label
on both sides, which is also usual in the case
of neck ring labeling, is followed by additional application of the foil in the area of
the crown cork by means of an application
bell – entirely without rotating brushes or
additional bottle rotation. This retains the
label structure.
Robustness for long life
The labeling stations also impress with their
extraordinary robustness. Maintenance is
not required until after 20,000 hours of
operation at the earliest. What makes the
cold glue labeling stations so dependable?
1. The rotation of the glue segments in
only one direction. This prevents vibration, overload, and wear.
2. The direct drive without additional gear
stages.
3. A conical coupling without play.
4. Multiple labyrinth seals.
5. The external circulated oil lubrication
system offers an additional advantage
in that the amount of lubricant and its
distribution can be accurately monitored. Lubrication is guaranteed regardless of station rotation.
6. An integral hot water spray, which
flushes off the gluing segments and the
glue drum, enables cleaning to be carried out without any problems.
All these plus points prompt Josef Tolar to
come to an extremely positive conclusion:
“KHS technology fulfills all of our requirements for precision, user-friendliness, and
robustness. Our products are therefore perfectly equipped for an attractive appearance at the point of sale.”
After the bottles have been labeled,
fill levels and labels are checked by an
Innocheck PROMECON 4000. The next step
is packaging. Here, KHS has equipped the
second line with a new KHS Innopack Kisters
WP 60 wrap-around packer as part of the
third modernization step. This works at 60
cycles/minute and enables beer bottles to
be packed in a variety of formations. The
machine can be changed over for new pack
formations in an extremely short time. This
gives rise to the maximum efficiency. An
additional gift inserter allows extra items
to be inserted into the wrap-around cartons. In this way, the company can implement sales promotion measures, which contribute to a high degree of customer loyalty.
The course is therefore set for the
further growth of Budweiser Budvar. According to Master Brewer Tolar, KHS will “continue to be a trusted partner.” Something
beer drinkers around the world will appreciate.
Lubomir Neubauer, Manager of the KHS Branch
Office in the Czech Republic, KHS AG, Budweis
fi
INFOBOX
• WEBSITE www.budweiser-budvar.cz
• CONTACT
Lubomir Neubauer, Manager of the
KHS Branch Office in the Czech
Republic, KHS AG, Budweis
Tel:
+420 385 515 102
E-mail: lubomir.neubauer@khs.com
WELLNESS PRODUCT KNORR VIE: KHS IS TURNKEY SUPPLIER
La
en bouteille
Until now, one had to peel vegetables and fruit in order to gain access to the daily vitamin intake. Now
Knorr, the Unilever brand, offers bottled nutrients and vitamins under the name Knorr Vie. As turnkey supplier, KHS ensures perfect production conditions and recently received Unilever’s Flexible & Professional
Project Management award in recognition of its performance. The team is proud of this achievement.
task+solution °
1
THE TASK
Perfect testing, cooling, and labeling quality for demanding
small bottles and comprehensive data control in the production process.
2
THE SOLUTION
As turnkey supplier KHS installed
• advanced monitoring and inspection technology,
• an Innopas bottle recooler,
• two Innoket HL 2040 labeling machines, and
• a Plant Information System (AIS).
Nutrition experts recommend eating a minimum of 400 grams of
fruit and vegetables per day. However, these days we often don’t
have the time for peeling and chopping fruit and vegetables in
order to provide adequate amounts of vitamins and nutrients for
the body. The Unilever food group therefore came up with an
alternative in the form of the Knorr Vie fruit and vegetable product, which is not only very tasty but also provides 50 percent of
the recommended daily intake of fruit and vegetables in a single 100 milliliter bottle – without any chopping or peeling.
The healthy shake comes in four flavors – pineapple-passion fruit-corn; apple-carrot-strawberry; banana-pumpkin-kiwi
fruit, and orange-banana-carrot – and is very popular with European consumers. Each of the sophisticated recipes mixes two
fruits with a vegetable, thereby creating new, delicious taste
experiences. Knorr Vie consists of only concentrated juice and
nourishing fruit puree – it contains no added sugar, artificial
additives, or artificial flavorings.
Knorr Vie was initially launched in the Netherlands. Meanwhile, consumers can enjoy the vitamin boost in Spain, Britain,
Belgium, Greece, Ireland, France, Germany, Austria, Sweden,
Norway, Finland, Denmark, Portugal, and Switzerland.
Until 2006, Knorr Vie was exclusively produced in Germany – since the end of January 2007, the wellness products are
also produced by PTZ, a Czech company near Prague. PTZ has
been part of the Unilever Group since 1992 and until 2005, was
specialized in the production of soap and cosmetics in addition
to food products. Today, the company is a pure food producer
24*25
with a product range covering margarine, fat spreads, mayonnaise, salad dressings, mustard, and ketchup. Knorr Vie is the
most recent addition to the product range. Pavel Sládek, Project Manager at PTZ, says, “PTZ is proud to have been chosen to
produce Knorr Vie. Our staff has had a strong affinity with this
new wellness product right from the start.”
AMBITIOUS PLANS
PTZ produces more than 100,000 tons of different food products
every year. Sládek looks ahead: “We are well prepared for further growth of Knorr Vie. Our new line has capacity for producing up to 140 million bottles per year, and we have space for
additional filling and packaging systems.”
PTZ chose KHS line equipment for good reasons: “We were
guided by the positive experience of our Group with filling and packaging of Knorr Vie in Germany, and it therefore didn’t take us long
to choose KHS technology and KHS as turnkey supplier,” says Pavel
Sládek.
KHS supplied the line with a capacity of up to 55,000 100ml bottles per hour, including the following components
* X-ray fill level monitoring
* Headspace sterilizer
* Mass formation
* Innopas bottle recooler with advanced DTS-C technology
* Two Innoket HL 2040 labeling machines
* Buffer system
* Label position checker
* Packaging and palletizing equipment
* A Plant Information System
It thereby meets and all requirements of the Czech client, as
outlined below.
2
*
*
*
*
*
THUMBNAIL PORTRAIT: KNORR
2.3 billion yearly sales
Represented in more than 100 countries
Biggest food brand of the Unilever Group
PTZ has been part of the Unilever Group since 1992
PTZ has been focusing purely on food production since 2005
Top Many, many small Knorr Vie bottles: PTZ has ambitious plans.
Bottom KHS labeling equipment: Perfectly meets the Unilever requirement of an attractive appearance of Knorr Vie at the point of sale.
PARAMETER: EXACT FILL LEVELS
After the bottles have been filled and sealed with aluminum caps,
the KHS fill level monitoring system checks fill levels using Xray technology.
PARAMETER: OPTIMUM HYGIENE
The system channels out underfilled or overfilled bottles, while
properly filled bottles are sent to the headspace sterilizer located
directly after the fill level check. The sterilizer ensures maximum hygiene. A clamping jaw conveying system transports the
bottles to a certain level and puts them in a side position so that
the inside of the headspace is fully wetted with product and
therefore re-sterilized due to the high product temperature. This
creates ideal hygienic conditions. The door-like design of the
clamping jaw conveying system provides optimum access to the
system.
PARAMETER: GENTLE PROCESSING
2
ADVANTAGES OF KHS TECHNOLOGY
Specifications
Customer benefits
* X-ray fill level monitoring
*
Perfect filling
* Headspace sterilizer
* Innopas bottle recooler with
temperature zones
* DTS technology in Innopas
infeed and outfeed areas
* Special buffer table design
*
*
Optimum hygiene levels
Gentle product handling
*
* Operation of two labelers
*
Unproblematic run-out during
product changeover
Optimum utilization of production
space, gentle bottle conveying
Operation can continue at only
slightly reduced speed during
servicing of one machine
Maximum labeling precision
*
* Camera inspection and
VarioDrive
* Bus system
*
* Hot melt labeling
*
* Rapid glue setting
* Plant Information System
*
*
*
Continuous corrections ensure
perfect label positioning
Cost-cutting, low glue
consumption
High labeling speed
Analysis/control of all production
steps
The bottles then enter the Innopas bottle recooler via the mass
formation unit, which gently extracts heat from the bottles
through sprinkling with water until they have reached a temperature of 20 degrees Celsius. Cooling takes place in finely graduated temperature zones. A counter-flow of water is circulated
to the bottles. The infeed and outfeed areas of the recooler are
equipped with new DTS-C technology that prevents bottles from
being left behind in the unit during run-out or during intermittent operation for product changeover.
PARAMETER: HIGH LINE EFFICIENCY
Buffer segments offer ample capacity for holding bottles temporarily during system downtime. The buffer table is designed
to make optimum use of the production space and to ensure gentle processing of plastic bottles.
PARAMETER: PERFECT LABELING
KHS labeling technology ensures perfect appearance of the Knorr
Vie bottles at the point of sale. The two Innoket HL 2040 labeling machines with a pitch circle diameter of 1.180 millimeters
each have a capacity of up to 33,000 bottles per hour. This ensures
maximum availability. When maintenance work is carried out on
one machine, the other one can continue to operate with only
slight impact on line speed. Before the bottles reach the labeling machine, a blower removes any water remaining on the bottles after the recooling process.
The wrap-around paper labels must adapt to the square
bottle shape during hot melt labeling. The labeling process starts
at one bottle edge in order to ensure precise positioning of the
task+solution ° Wellness Product Knorr Vie: KHS is Turnkey Supplier
labels. A camera inspection unit in conjunction with the electronic VarioDrive bottle turret control system ensures the required
precision. Two fixed cameras monitor the exact position and
alignment of each individual bottle. A bus system processes the
associated information and transmits instructions for any rotational movements that may be required to correct the position
of each bottle directly to the VarioDrive.
The hot melt technique offers two main benefits:
* low glue consumption through pure initial and final gluing
* perfect positioning at high labeling speed
Together with PTZ, KHS developed a special Innocoll adhesive
that is specifically tailored to the production requirements of
the Knorr Vie bottles. The quality and composition of the label
material and the interaction between adhesive, label, and bottle were analyzed extensively in the KHS laboratory. Based on
numerous test runs the team developed the optimum adhesive
composition for perfect labeling results. Finally, the experts
tested the application under production conditions. “The support provided by KHS was literally perfect all-round,” says Mr
Sládek approvingly.
PTZ decided to use an individual label approach, with
labels fed from a magazine as opposed to roll-fed labeling. Mr
Sládek says, “The precision achieved by the KHS labeling equipment at high speed is amazing. It leaves nothing to be desired.
The high flexibility, ease of use and hygienic design of the labeling machines are equally impressive.”
the operational status the line and its individual components in
detail and makes this information available at all times, thereby
facilitating rapid identification of weak points and troubleshooting. Downtime is reduced significantly, while line productivity
increases. Seamless documentation of processing data also facilitates quality assurance. Energy and media consumption can be
correlated exactly, controlled, and reduced.
AIS not only continuously monitors the actual state of
the complete line, it also enables data logging over longer periods and therefore facilitates comparative analyses. The individual machines are interlinked via Profibus. The AIS server makes
the collected data available for visualization purposes. In addition, the KHS equipment installed at PTZ is already equipped for
application of ReDiS mobile.
PTZ project manager Pavel Sládek says, “Our cooperation
with KHS was gratifying in every respect. As a company aiming
for maximum professionalism we value suppliers who also follow this maxim.” Proof of this appreciation wasn’t long in coming, to the delight of the whole team: KHS recently received
Unilever’s ’Flexible & Professional Project Management’ award.
Lubomir Neubauer, Manager of the KHS Branch Office
in the Czech Republic, KHS AG, Budweis
Thomas Ess, Global Key Account Manager Unilever,
KHS AG, Bad Kreuznach
PARAMETER: PRECISE LABEL POSITION CHECK
In order to ensure absolute reliability of the label quality, the
labeling process is followed by a label inspection in conjunction
with a second fill level check – just to be on the safe side.
At the packing station, cluster packs comprised of three
Knorr Vie bottles each are placed secondary carton packaging
for subsequent palletizing.
26*27
fi
INFOBOX
PARAMETER: COMPREHENSIVE INFORMATION CONTROL
• WEBSITE www.unilever.cz
Unilever operates according to the following principles. “Anyone who develops and produces foods bears great responsibility. During the entire production process including raw material sourcing, processing, and delivery of the end product we
insist on conscientious compliance with our strict quality and
hygiene guidelines.”
This task requires collection and analysis of a tremendous amount of data. The KHS equipment at PTZ handles the
task with ease because it is equipped with the AIS Plant Information System software. The data acquisition system monitors
• CONTACT
Tel:
+420 385 515102
Thomas Ess, Global Key Account Manager
Unilever, KHS AG, Bad Kreuznach
Tel:
+49 (671) 852-2682
E-mail: thomas.ess@khs.com
Kofola – everyone in the Czech Republic and Slovakia knows this name – for Kofola Cola is the
front-runner with young and old. But perhaps not everybody knows that KHS has a major share
in the drink’s outstanding quality.
1
THE TASK
Assisting a rapidly growing soft drink manufacturer at several locations with high-performance
filling equipment.
2
THE SOLUTION
Various models of
KHS Innokeg Till TRANSOMAT 5/1
keg technology with
• modular design,
• high-performance capability, and
• upgrading existing lines with state-of-theart DFC filling technology.
+++ 1962 Kofola Cola enters the market in the former
Czechoslovakia +++ 1989 Sales start to decline due to
opening up to the West +++ 1997 Kofola manufactured
under license by the beverage company Santa Napoje
+++ 2002 Santa Napoje buys brand rights and changes
its name to Kofola +++ 2007 Kofola is the leading Cola
brand in the Czech Republic and Slovakia / Merger with
the Polish beverage company Hoop +++ 2010 Expansion still far from complete +++
This is roughly how the telegram reporting the
success of the Czech beverage manufacturer Kofola would
read. However, Rene Musila, Chief Operations Officer
at Kofola, is rather more modest: “We had the great
task+solution °
28*29
Innokeg Till TRANSOMAT 5/1 line equipment: The DFC filling system saves product and uses
less carbon dioxide and nitrogen, and minimizes the oxygen pickup in the product.
good fortune to choose the right expansion
strategy and make the correct decisions. In
short, we had the right feeling for our markets and target groups.” As far as technical solutions are concerned, Kofola has relied
on keg technology from KHS for many years.
But first, a brief look back. The Kofola
soft drink started its triumphal march in the
Czech Republic more than 40 years ago.
Kofola soft drinks were sold for the first time
in 1962. The drink was extremely popular
in the former Czechoslovakia until 1989.
With the fall of the Iron Curtain, sales declined
strongly until Kofola was finally on the point
of closing in the middle of the 1990s. But
at this point, the then Santa Napoje company discovered the brand and initially bottled Kofola under license; the company then
purchased the brand rights in 2002. In the
meantime, the whole group calls itself by
the name of its flagship product: Kofola.
Press spokesperson Martin Klofanda
describes the situation today like this: “With
our extensive product range, we offer a large
selection of non-alcoholic beverages to a
wide target group, which ensures us a farreaching presence in our target markets of
the Czech Republic, Slovakia, Poland, and
Hungary.” Kofola intends to become one of
the three main manufacturers of non-alcoholic beverages here by 2010. Furthermore,
at least one or two brands are hoped to be
in first or second place in the ratings list
within the particular beverage segment in
each of these markets.
START OF COLLABORATION WITH KHS
KHS keg equipment has already been in use
in the company since 1999 – at that time, a
total of six Innokeg Till TRANSOMAT 5/1 were
used for racking kegs at the various Kofola
locations.
In 1999, Kofola invested in the first
KHS Innokeg Till TRANSOMAT 5/1 keg system in the Czech plant of Krnov. A complete
line with peripherals such as exterior washer,
keg weigher, and conveyors.
In 2000, the company had already extended
the line by the addition of a further Innokeg
Till TRANSOMAT 5/1, which was connected to
the existing plant equipment without any difficulties thanks to its modular design. Since
then, the peripheral devices have been working for both Innokeg TRANSOMAT 5/1 lines.
Output: until recently, a total of 120 kegs per
hour.
In 2002, Kofola in Slovakia decided
in favor of the Innokeg Till TRANSOMAT 5/1
with peripheral components at the Rajecka
Lesna site. Here too, this was followed in
2003 by the addition of a further Innokeg Till
TRANSOMAT 5/1 and an increase in line capacity to 120 kegs per hour.
The third Innokeg Till TRANSOMAT
5/1 was installed in Rajecka Lesna in 2006.
However, this is distinguished from its predecessors by a special feature: it is equipped
with the DFC (Direct Flow Control) filling system with which KHS overcomes the drawbacks
of gas counterpressure control in the filling
process. Rene Musila praises, “We were thrilled
with the DFC filling system from the very
beginning and therefore decided to convert
all the Innokeg Till TRANSOMAT 5/1 machines.”
The latest investment in KHS technology is
intended for the Czech Republic site of
Mnichovo Hradiste in 2007. An Innokeg Till
TRANSOMAT 5/1 with integral DFC filling
process and a capacity of 80 kegs per hour.
Kegs have around a 20 percent share of total
Kofola sales with the main target group of
young people in the 20 to 35-year-old age
group. The share of kegs is expected to increase
to up to 50 percent in the future. COO Musila:
2
THUMBNAIL PORTRAIT: KOFOLA
Top-selling cola brand in Slovakia
Kofola in second place in the Czech Republic
Recently also available in Hungary
Syrup drink Jupi very successful
Fruit drink family very successful (fruit juice
drink Jupik developed especially for children)
* Other well-known brands:
* Soft drinks Top Topic, Chito Tonic,
Sentino, Snipp, and RC-Cola
* Rajec mineral water in the form of
natural water and water flavored with
herb extracts.
*
*
*
*
*
Left Before the filling process (right): Interior keg washing. Center Innokeg Till TRANSOMAT 5/1: Outputs 120 kegs per hour.
Right Held exactly in place: The keg during the washing and racking process.
Above Keg connoisseurs: Martin Klofanda, press
spokesperson for Kofola (left) and Lubomir Neubauer,
Manager of the KHS Branch Office in the Czech Republic.
2
THE SECRET OF KOFOLA COLA
Fourteen natural ingredients give Kofola its incomparable taste. About thirty percent less sugar and
approximately fifty percent less caffeine than other
cola drinks make Kofola particularly easy on the
stomach. The original recipe of 1962 is used to the
present day.
“Kofola is a high-price and high-quality product. For this reason, we can only afford to
collaborate with a manufacturer of high-quality system equipment. And that is KHS.”
Kofola has been able to considerably increase
capacity by converting all its present lines
to the DFC filling process. In Krnov as in
Rajecka Lesna, the Innokeg Till TRANSOMAT
5 / 1 machines now fill 70 kegs per hour
instead of 60. The latest Innokeg Till
TRANSOMAT 5/1 in Rajecka Lesna even achieves
80 kegs per hour.
An important quality aspect: because
of the precise control of the volume flow at
the beginning of the filling process, Kofola
achieves high performance with extremely
low oxygen pickup and minimal gas losses.
Musila: “The aspect of achieving a further
increase in quality using the DFC system was
the deciding factor for us.”
KHS equipment even ensures that
the kegs are perfectly prepared before the
actual filling process. This starts with washing keg interiors. The washing process is
monitored by a pressure sensor and a wet/dry
sensor. When the keg is undocked from the
washing station, the fitting closes automatically; this safeguards the sterile condition
of the keg. Before it passes into the racker,
the system automatically checks the residual pressure and channels out faulty kegs.
The same also happens, incidentally, when
the keg is transferred to the interior washer.
The Innokeg Till AK 1 exterior washer
also ensures perfect cleanliness from the
outside. A further important component of
KHS keg technology, according to Musila, is
the modular design of the system. The lines
can therefore be easily extended by installing
additional components.
Kofola currently fills 30-liter and 50liter kegs. If new developments should also
require smaller kegs, Kofola is already prepared today with flexible KHS technology.
And even the older model Innokeg Till
TRANSOMAT lines can be easily adapted by
means of minimal modifications. Kofola’s
telegram of success is becoming longer and
longer.
fi
INFOBOX
• WEBSITE www.kofola.cz
• CONTACT
Lubomir Neubauer, Manager of the
KHS Branch Office in the Czech
Republic, KHS AG, Budweis
Tel: +420 385 515102
task+solution °
30*31
Krombacher Brauerei explores new avenues
The
Fresh Keg
The Krombacher Brauerei is the first and so far the
only provider in Germany of the so-called ’fresh keg’,
a development from Heineken and marketed globally
as the DraughtKeg. KHS keg technology is included.
The latest in tapping technology: A CO2 cartridge keeps the
The Krombacher Brauerei has always been known for
groundbreaking innovation on the market. Now the
Krombacher fresh keg is in German grocery stores, a 5liter DraughtKeg, which keeps its contents very drinkable after tapping, for up to 30 days. The secret of this
innovative tapping technology developed by Heineken:
There is a CO2 cartridge in the 5-liter can, which makes
problem-free tapping possible anywhere (the disposable accessory needed is neatly packaged with the container) and ensures constant freshness. Thanks to its
compact form, the keg is easy to carry, and an ideal
accompaniment for pleasant evening barbeques, parties, and other outdoor activities. In restaurants, too,
it would be quite easy to use.
Krombacher fills the fresh kegs using technology from KHS. More precisely: In spring of 2007, the
first KHS Innokeg Till MULTIBLOC machines at Krombacher went into production – the same type of system,
incidentally, also processes the classical 5-liter can. A
MULTIBLOC system can be built on a modular basis, each
individual machine processing, depending on its details,
processing 400 to 700 5-liter DraughtKegs per hour.
The system can be extended with no problem. In the
Netherlands, three systems are already operational,
with a capacity of up to 2,800 kegs per hour each. In
Germany, the Krombacher Brauerei finds the outstand-
ing filling quality compelling, along with the high capacity of the MULTIBLOC machines. Features, which grant
the Innokeg Till MULTIBLOC concept unique characteristics in the quickly growing market segment.
With the Innokeg Till MULTIBLOC series, KHS has
been systematically extending its portfolio of classical
keg technology since 2005.
And consumers like it: Currently there are requests
from Europe, the U.S., and Asia for the Innokeg Till
MULTIBLOC machines.
beer fresh, even weeks after
tapping.
Jörg A. Lauer, Product Support / Technical Sales Manager,
Competence Center Keg Technology, KHS AG, Kriftel
fi
INFOBOX
• WEBSITE www.krombacher.de
• CONTACT
Jörg A. Lauer, Product Support / Technical Sales
Manager, Competence Center Keg Technology,
KHS AG, Kriftel
Tel: +49 (6192) 491-206
E-mail: joerg.lauer@khs.com
Ukraine: Olimp sends spirits subsidiary Prime on the road to success
The Prime of Vodka
The Ukrainian spirits company Prime, recently founded in 2006, is already one of
the biggest on the national vodka market – with KHS technology, they have invested
three times in enormous growth and outstanding quality.
1
THE TASK Installation of vodka bottling tured a market share of about 25 percent.
lines in the medium-capacity range, which Taking a closer look at the individual market segments, the balance of success for
• meet the strictest of quality standards
rather less-expensive vodkas is even more
and
impressive where Olimp, with 73.7 percent,
• require a minimum amount of time for
is clearly the market leader.
changeover.
NEW BRANDS FOR NEW MARKETS
At the end of 2006, according to Albert
Melikbegyan, Prime’s General Director, the
KHS lines
group achieved even higher impact in the
• equipped with a single-chamber normal middle price segment with the new brand
Prime. There are ambitious plans associpressure Innofill MFN/P filling system
ated with that: “Our goal isn’t just oriented
with central fill level adjustment, and
towards increasing production. We would
• Clean Design, as well as
much rather use Prime to reach the vodka
• maximum line efficiency.
buyers in the medium and high price segments more and more. We are proceeding
step by step and are capturing new positions in the market.”
Among experts, good vodkas are not just
And the group has prepared for this
popular; their quality makes them success- strategic decision for a long time. Even in
ful. That’s no different in the Ukraine than 2003, Olimp had decided to build the new
in other countries. This might be why the greenfield Prime vodka factory. The comUkrainian beverage manufacturer Olimp pany found the suitable location in the
named two of its vodka brands the way it beautiful village of Malinovka in Chuguyev
did: ’Wdala’ is the Ukrainian word for suc- Province, near the large city of Charkov.
cessful, and ’Uljublena’ means popular. After three years of construction, the plant
And Olimp is indeed very successful on the went into production in 2006.
Ukrainian spirits market.
Anyone seeing the building and
Although the company originated
facility’s equipment has to notice that the
only eleven years ago from a former food name Prime is part of the program: Prime
manufacturer, last year alone Olimp’s six means the best. “In fact, besides the best
vodka brands established since 2000 cap- in ingredients, we have the best technical
2
THE SOLUTION Three complete
equipment here, too. And only with that
is the production of the top quality vodka
possible, after all,” says Viktor Pavlov,
Prime’s Technical Director. And because
the best is just good enough, Olimp started
the new Prime family of vodka brands when
the facility was opened.
Not without reason, because for
Prima vodka, not only are excellent raw
materials used, but also the water is taken
from 750-meter-deep springs, making production independent of external water
sources. All in all, independence is an
important topic in the very broadly positioned Olimp conglomerate. Management
thus ensures that vodka production has a
large vertical depth in the group: To remain
largely independent of suppliers, Olimp
built a production facility for closures
directly next to the vodka factory. But
that’s not all, a glass works is also currently
being built close by. This allows Prime to
use high-quality materials, which need not
be transported over great distances.
task+solution °
32*33
Left Innofill MFN/P filling system: Operates with pipette
effect and low oxygen uptake, while retaining product
aroma. Below A bird’s eye view of Prime: Recognizable
even from the air.
2
THUMBNAIL PORTRAIT: OLIMP
Olimp has more to offer the Ukrainian market than
a number of spirit and vodka specialties. The company also produces wines, brandies, alcopops, and
soft drinks, such as iced tea. Early 2006, Olimp
brought the Yuventa iced tea to the market. By the
end of 2006, Yuventa had already captured a 10.5percent of the iced tea market in the Ukraine.
But outside the beverage market, Olimp is also successful – for instance in the areas of hotel management and restaurants, as a casino operator, and a
perfume manufacturer, in construction and agriculture.
CONSISTENT QUALITY STRATEGY
Another important topic is Prime’s high quality expectations. That such consistent quality strategies pay off again and again is
shown by the sales record achieved by the
company in the first three weeks after the
start of Prime vodka. In that brief period
of time, the company sold one million bottles of Prime. Director Viktor Pavlov explains
this unusual success with a great deal of
understatement. “The consumers liked our
products.”
On the other hand, awards won by
the vodka brand are also indicators of high
quality. During the big Ukrainian food conference ’World Food Ukraine 2006’, all five
Prime vodkas took first place in their individual categories, and were awarded gold
medals. At the international tasting competition Prodexpo, the Prime brand received
two additional high awards. With such striving towards quality, it is almost unavoidable that Prime should also rely exclusively
on the best and latest technology in their
production facilities: In Malinovka, three
KHS lines are already in operation. An
overview of the components:
* Innopal ASH depalletizing robot with
empty bottle inspector,
* mechanically controlled, single-channel Innoclean FR-EM rinser,
* single-chamber normal pressure Innofill
MFN/P filling system, with pipette effect,
* Innofill SV screw capper,
* Innoket KL 2060 labeling machine,
equipped with four adhesive-pressure
labeling stations,
2
THE SPECIAL MIXTURE
The Prime brands Superior and World Class are classical styles of vodka with an alcohol content of 40
percent and – like other vodkas – wheat and rye as
their basic ingredients. Euro Standard has an alcohol content of 38 percent and is therefore a little
lighter in taste. An 80-proof vodka, Ukrainian Special is flavored with thyme and fennel. Another
extremely interesting combination of ingredients
is found in the 80-proof vodka Honey Spice: It is
spiked with the flavors pepper, ginger, and honey.
2
Left VarioDrive and camera technology: Difficult
ALL SUGAR
labeling of vodka bottles with adhesive-pressure labels and perfectly solved for exactly
KHS not only provides Prime with complete system
technology, but also equipped the syrup room. The
sugar preparation system is comprised of the following components:
* Sugar dissolver for batch operation
* Sugar pasteurization
* Sugar filtration, and
* Sugar syrup storage tank
*
*
KHS Innocheck ETI label inspection,
and
Innopal PBL palletizer with level compensation.
specified areas. Right Albert Melikbegyan,
Prime’s General Director: “For us, KHS system
technology is active future proofing for our new
Prime brand.” Bottom KHS Line Equipment:
Space-saving and yet user-friendly, integrated
into existing spaces.
significant component of the success of
the company,” praises Technical Director
Pavlov.
COMPLETE SOLUTION FROM KHS
But how does Prime produce a vodka that
tastes good for the whole world? Of course,
the technical equipment is very important.
And Olimp researched it very thoroughly
before investing: “On site in Germany and
Italy, we became convinced that practically all modern plants are working with
KHS line technology and that their employees only speak positively about German
machine technology. The visit to the KHS
plant in Germany also convinced us of the
high level of the system technology on
offer. KHS system technology is now a
An important point when deciding on KHS
was that KHS was able to provide the complete solution as a sole-source supplier –
a fitting complement to Olimp’s strategy
to work only with a few select partners.
KHS installed three complete plants
in Malinovka, with a bottling capacity of
12,000 bottles per hour each. Currently,
the lines are processing 0.25-liter, 0.5-liter,
and 0.75-liter bottles. The low reconfiguration times af ter bottle and product
changeover ensure the highest possible
system efficiency.
FULL CONTROL WHEN DEPALLETIZING
At the first station in each line, the Innopal
ASH glass bottle depalletizing robot unloads
the vodka bottles in a particularly gentle
manner. Then the Prime contour bottles
are pulled off row by row. The empty bottle inspector checks the side walls, the
mouth, and the base of each individual bottle. Only perfect bottles reach the rinsing,
filling, and capping system.
RINSING WITH PURE VODKA
The mechanically controlled Innoclean FREM single-channel rinser rinses the bottles with a circulation system of pure vodka.
After the rinsing process, the vodka enters
a catch basin where it is cleaned for subsequent use to clean more bottles.
task+solution ° Ukraine: Olimp sends spirits subsidiary Prime on the road to success
HYGIENICALLY DESIGNED
FILLING SYSTEM
The heart of the line is the Innofill MFN/P
filling technology. “This filling system
enables us to achieve outstanding filling
results with no loss of flavor whatsoever.
For an operation as focused on quality as
ours, that’s a very important item,” explains
Pavlov. The single chamber Innofill MFN/P
filling system uses a filling tube with a
foot valve. The multi-stage filling process
includes the following steps:
1. Open the filling valve while lifting the
bottle.
2. Discharging the air inside the bottle
through a return air tube, while vodka
is flowing into the bottle.
3. End of the filling process when the fluid
level reaches the lower edge of the filling tube.
A highlight: the pipette effect. Directly
after the end of the filling process and before
the bottle is lowered, the electrically controlled pneumatic cylinder integrated into
the filling system closes. It is connected to
the return air tube. The pipette effect automatically takes effect once the fill level is
reached, which ensures that the remaining
liquid remains in the return air tube. The
result: an absolutely no-drip process and
extremely gentle product handling. The system releases the product retained in the
return air tube once the next bottle is centered – just before the bottle is pressed
against the filling valve and the filling valve
is opened.
The specific benefits: The Innofill
MNF-P filling system operates with minimum oxygen pickup and guards exceptionally well against loss of product flavor while
satisfying maximum microbiological requirements. Thanks to a special design, sanitizing time can be minimized without negative affects on hygiene. Smooth passages
and surfaces are the rule throughout the
filler, from the ring vessel to the filling
valves. In the valve area, membrane technology is used. The smooth surfaces of the
filler also offer great advantages during
CIP sanitizing. All that is needed for CIP
cleaning is to attach rinsing sleeves to the
filling valves. Then the entire filling system can be rinsed by circulating caustic,
water, steam, or other cleaning media.
The Innofill MFN/P also has a central fill level adjustment, allowing easy
changeover to different bottle sizes at the
push of a button.
The Innofill SV screw capper, finally,
is continually and individually supplied with
caps by an automatic cap feeder. Fill level
and cap checking follows the rinsing, filling, and capping process. Faulty bottles are
reliably rejected by the system.
PERFECT LABELING
And labeling? An Innoket FL 2060 solves
that task. It is equipped with four adhesive-pressure labeling stations. An additional cold-glue labeling station attaches
and subsequently applies tax revenue stamps
on the bottle necks. The Innoket FL 2060
is equipped with VarioDrive – in combination with camera technology.
A KHS Innocheck ETI label inspector checks that the labels are perfectly positioned. Here, the system does not simply
check the seating of the labels, but also
whether the labels are applied in the correct relationship to one another on the bottle.
The freshly labeled bottles are then
conveyed onto up to six lanes – corresponding to bottle size and the type of packaging and packing formations desired for
packaging. At Prime, these can be tray
shrink packs or wrap-around cartons.
PALLETIZING WITH LEVEL
COMPENSATION
An Innopal PBL designed according to the
innovative KHS modular concept then palletizes the finished packs. The palletizer
34*35
in operation at Prime has a level compensator and an extension of the layer pusher
towards a full bottle conveyor. Thus, the
layer pusher simultaneously acts as a row
pusher setting up the layer formations and
palletizing at the same time. Once the pallets are secured, they are transported by a
forklift to the warehouse.
PREPARED FOR THE FUTURE
With the comprehensive KHS performance
package, General Director Melikbegyan considers himself perfectly prepared. “For us,
KHS system technology is active future
proofing for our new Prime brand.” Prime’s
boss looks optimistically towards the future.
Currently, Olimp is among the five largest
Ukrainian spirits manufacturers. The new
Prime plant will help, says Melikbegyan, in
their rise to leadership of the industry,
whether in the short term, medium term,
or long term. Then Olimp will finally have
climbed the Olympus of the Ukrainian spirits industry.
Jaroslaw Niebisch, Sales Manager, Ukraine,
Ludmila Enke, Manager of the KHS
Branch Office in Kiev
fi
INFOBOX
• WEBSITE www.olimp.ua
• CONTACT
Jaroslaw Niebisch, Sales Manager, Ukraine,
Tel: +49 (671) 852-2608
E-mail: jaroslaw.niebisch@khs.com
Ludmila Enke, Manager of the KHS Branch Office
in Kiev, KHS AG
Tel: +380 444 619362
E-mail: ludmila.enke@khs.com
Sarajevo Brewery relies on
multi-function ACF technology
TripleJump
Sarajevo Brewery has enjoyed dynamic growth for many years. Sales have tripled compared
with ten years ago. KHS supports the company with forward-looking plant and process technology –
currently in the form of an ACF line that can process three totally different beverages.
1
THE TASK Installation einer
A combined line for aseptic filling of fruit drinks, beer, and carbonated soft
drinks.xible
n Abnie für das schoKräuterlikör.
2
THE SOLUTION
KHS provided a customized ACF bottling line based on dry sterilization and
numerous components for ensuring high flexibility and efficiency.
The history of Sarajevo Brewery began in
1864. Since it was established, Sarajevsko
Pivara, which is today’s name of the brewery in the local language, has experienced
numerous ups and downs – just like the
city of Sarajevo. However, since it was privatized around ten years ago, the company has been remarkably successful:
* Beer output increased from 110,000
hectoliters in 1997 to 380,000 hectoliters in 2006
* Sales of non-alcoholic beverages
increased from 50,000 to 150,000
hectoliters
Accordingly, the brewery has optimistic
plans: This year the group aims to achieve
total sales of 630,000 hectoliters, compared with 530,000 in 2006. The signs are
good, and the company may even exceed
this target – with a sales ratio of 70 percent beer and 30 percent non-alcoholic
beverages. After all, during the first quarter of 2007 output increased by 18 percent.
This makes Sarajevsko Pivara the
Number One brewer in Bosnia and Herzegovina. The company realizes 95 percent
of its beer sales with the traditional light
Sarajevsko pivo, three percent with the
premium beer Heinrich Löwe (this is the
name of the Viennese industrialist under
whose management the brewery prospered
around 120 years ago), and two percent
with non-alcoholic beer. The alcohol-free
beer, which was only introduced in 2006,
has become well established within a few
months, and not just in the home market.
The new product is also very popular in
Libya. Sarajevo Brewery’s other beer styles
are sold mainly in the home market. The
successful company from Sarajevo ranks
second in the country for soft drinks. The
task+solution °
Left Sarajevo Brewery relies on quality: Investments over the past ten years amounted to
around €70 million. Top Fruit juice drinks are filled in PET bottles, based on the dry steriliza-
2
36*37
THUMBNAIL PORTRAIT:
SARAJEVO BREWERY
tion process.
high-quality mineral water range is also
very popular and is even sold in the U.S.A.
Last year, Sarajevsko Pivara also expanded
its range of fruit juices and fruit drinks.
This decision quickly turned out to be a
hit. The fruit juices in flavors such as
orange, strawberry, blueberry, multivitamin, and apple are already big sellers.
Fruit drinks with 12 percent fruit content
are available in the same flavors (except
apple). Sales are mainly driven by the multivitamin style with a 40 percent share.
Fruit juices are exclusively sold in
glass bottles. Fruit drinks leave the plant
in stylish PET bottles with sizes ranging
between 0.25 and 2.0 liters.
In order to be able to offer the market top quality the company decided to
use a combined KHS-ACF (Aseptic Cold Filling) bottling line based on the innovative
dry sterilization process. Brewery Manager Nazif Brankovic says, “With this type
of aseptic bottling we deliberately chose
a technology that offers plenty of future
potential.”
Incidentally, the ACF line is not the
first system KHS has delivered to Sarajevo. Within the past five years, Sarajevsko Pivara also invested in a KHS glass
line with a capacity of 50,000 0.5-liter bottles per hour, as well as a KHS keg line with
a capacity of 60 50-liter kegs per hour.
Nazif Brankovic’s comment couldn’t be
more enthusiastic: “Since they were commissioned the lines just keep running without any problems, and they are also very
efficient.”
Hilmo Selimovic, President and
main owner of Sarajevo Brewery, explained
the reasons for the decision to install special ACF bottling equipment from KHS at
this stage: “With aseptic cold filling based
on dry sterilization KHS clearly plays a pioneering role that we wish to utilize.”
For Sarajevsko Pivara, dry sterilization has benefits compared with the tra-
1864 First industrial company to be established in
Bosnia and Herzegovina.
1997 Output: 110,000 hl of beer, 50,000 hl of nonalcoholic beverages
2006 Output 380,000 hl of beer, 150,000 hl of
non-alcoholic beverages, target for
2007/2010: total of 630,000/800,000 hl
Product range: Beer, including Sarajevsko pivo and
the Heinrich Löwe premium brand, non-alcoholic
beer. Non-alcoholic beverages such as carbonated
soft drinks, the complete Pepsi range, fruit juices,
fruit drinks, syrup products, carbonated and noncarbonated mineral water
Investment volume: around €70 million over the
past ten years
ditional wet process, while offering similar high safety standards. The dry version
makes rinsing of the PET bottles with disinfectant and water within the ACF block
unnecessary. The process also significantly reduces the space requirement of
Top Versatile shrink packer: Optionally 6-, 12-,
or 24-packs. Below Impressed by the KHS
ACF aseptic cold filling process: Nazif
Brankovic, Executive Vice President (left), and
Sajo Kolasinac, Technical Manager of Sarajevo
Brewery.
the ACF system compared with conventional wet systems (15 instead of 65 cubic
meters).
THE LINE CAN HANDLE THREE
DIFFERENT BEVERAGE STYLES
The special advantage of this line is that
it can handle all products sold by Sarajevo
Brewery in PET bottles, including fruit beverages, beer, and carbonated soft drinks.
The system currently handles the
complete range of fruit drinks and all PET
bottle types for these products. The line
has a capacity of 12,000 2.0-liter bottles
per hour.
HOW THE LINE NOW WORKS – IN
SLOW MOTION:
*
*
*
*
Blowing and conveying. An Innoline
LTR air conveyor delivers the freshly
blown PET bottles to the ACF block.
Mini-isolator technology. The block
is based on ’mini-isolator’ technology:
Class 100 clean room conditions are maintained by very specifically controlling
the sterile air within the mini-isolators
using HEPA (High-Efficiency Particulate
Air) filters.
Sterilizing. The PET bottles first enter
the sterilizer/activator area of the ACF
block over a format part-free infeed plate
with integrated, frequency-controlled
drive. Here is where sterilization takes
place, inside and out.
Filling. Non-carbonated beverages are
filled in PET bottles without pressure
through a two-stage, free-flow filling
*
valve. If required the system could also
process 100% fruit juices or viscous, noncarbonated drinks containing pulp or
cereals.
Capping. The next station is the ACFcompliant capper. The KHS Innofill SVACF unit integrated into the system was
specially designed for this process. It
is characterized by simple and hygienic
design. Consistent twisting force offers
increased cap-opening convenience for
consumers.
The brewery uses either sports caps or traditional plastic screw caps for fruit drinks.
In both versions, the caps are sterilized
with H2O2 before they are applied to the
PET bottles. While the actual sterilization
takes place in separate units, the cap feed
and the Innofill SV-ACF capper are designed
to handle both sports caps and plastic
screw caps. Capped bottles are conveyed
out of the ACF block and thus out of the
clean room.
* Inspection. The Innocheck PROMECON
2000 handles the task of checking fill
levels and caps.
* Labeling and packing. The bottles
then pass through amply sized buffer
segments to the sleeve labeler – directly
towards the Innopack Kisters SP 35 shrink
packer.
* For 6- and 12-bottle packs, the servocontrolled Innopack CSM handle applicator applies handles to the shrink packs.
The two conveying belts controlling conveying in the Innopack CSM run at slightly
*
different speeds thereby create small
gaps between each of the packs. An
application head dips into this space
and applies the handles precisely to the
packs.
Palletizing. The packs are palletized
by an Innopal PBL palletizer equipped
with a low-level infeed and based on the
KHS modular dry area concept. An automatic slip-sheet inserter is integrated
in the palletizing process.
Brewery Manager Brankovic is satisfied
with the benefits offered by this system:
“In addition to the innovative ACF block,
we value the fact that we can process all
our PET-bottled products on a single line
and with a further rinser-filler-capper
block.”
OPTION: BEER AND
CARBONATED BEVERAGES
In addition to PET bottles for fruit drinks,
the blow molder can also produce PET bot-
task+solution ° Sarajevo Brewery relies on multi-function ACF technology
38*39
Top Innopack Kisters PRIMUS SP 35 shrink packer: Controlled placement
of PET bottles. Below Innoket RF 25: Applies wrap-around paper labels
to the PET bottles.
2
EXPANSION: GLASS LINE FOR TUZLA
In 2006, Hilmo Selimovic, the main owner of Sarajevo Brewery,
acquired a controlling interest in the brewery at Tuzla, the third
largest city in Bosnia and Herzegovina. A new KHS glass line with
a capacity of 36,000 bottles per hour forms the basis for more growth
(2006: 190,000 hectoliters of beer, 20,000 hectoliters of mineral
water). “We regard KHS line equipment as a key component for the
success of our whole system,” says Mr Selimovic, commenting on the
decision to use a KHS line. For him, KHS is ’a trusted partner’.
tles for beer and carbonated soft drinks.
While PET bottles for fruit drinks have a
bottle mouth diameter of 38 millimeters,
the bottle mouth diameter for other beverages is 28 millimeters. Freshly blowmolded PET bottles with a bottle mouth
diameter of 28 millimeters enter the
Innoline LTR air conveyor track by a diverter.
It guides the bottles further directly to a
traditional rinser-filler-capper block located
next to the ACF block.
For soda pop, Sarajevsko Pivara uses
0.33, 0.5, and 1.0-liter PET bottles. Drinks
from the Pepsi product range are filled in
0.5, 1.0, and 2.0-liter PET bottles. For beer,
0.5, 1.0, and 2.0-liter PET bottles are used.
All these bottles move directly to the
Innoclean FR-EM single-channel rinser where
they are rinsed with water. Filling is handled by an electronically controlled Innofill
DRF triple-chamber filling system. This
long-tube filling system fills from the bottom up and therefore ensures a particularly gentle filling process with minimum
oxygen pickup. Filled bottles are conveyed
to an Innoket RF 25 roll-fed labeling machine
that applies wrap-around paper labels to
the PET bottles. The following processing
steps are identical to those for fruit beverages.
“With our new KHS line are we well
prepared for all eventualities,” says President Selimovic. In addition to the flexibility of the KHS line, the management
also values highly the integration of KHS
process engineering in the system, which
includes CIP equipment, flash pasteurizer,
and the Innopro PARAMIX CMX blending
system. The latter handles the task of continuously producing carbonated and noncarbonated soft drinks and integrates the
processing steps of deaeration, dosing and
mixing of water and syrup, and subsequent
carbonating in a single unit. In addition,
the concept of ’all from one source’ eliminates interface problems for the brewery.
For Sarajevsko Pivara, these are
good reasons for expanding cooperation
with KHS even further in future. Who
knows, perhaps we will see a ’quadruple
jump’ soon?
Manfred Keller, Sales Manager Southeast Europe,
fi
INFOBOX
• WEBSITE www.sarajevska-pivara.ba
• CONTACT
Manfred Keller, Sales Manager Southeast Europe, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2655
E-mail: manfred.keller@khs.com
Conqueror
of the Peak
Vitaminka in Banja Luka has more than quadrupled production in five
years. Now the company primarily wants to grow stronger yet in the area
of fruit beverages. The necessary system technology will come from KHS.
1
THE TASK
Flexible filling and packaging technology of the highest quality as the
foundation for tremendous national
and international growth.
2
THE SOLUTION
An innovative KHS glass line
(hot filling)
• able to bottle all fruit drinks such
as fruit juices, nectars, syrups,
fruit juice beverages
• as well as carbonated soft drinks
Mountain climbers know it. Once you’ve
climbed a peak you’ve had your eye on,
you want to go on to the next higher one.
The unstoppable climb of Vitaminka actually started less spectacularly, from a poetic
standpoint certainly in the foothills.
The little company in Banja Luka
in today’s Republic of Bosnia and Herzegovina – founded in 1947 – concentrated
on processing wild berries in the early
years. Gradually, Vitaminka expanded their
assortment with jellies, preserves, jams,
and canned vegetables. Later still came
the small-scale production of fruit juices.
In none of these segments did Vitaminka
rank among the big companies. That has
changed since 2002, the year the private
company was converted to a publicly traded
corporation. Kreis Industriehandel AG in
Basel holds the largest portion of the
shares, 76 percent, with the remaining
shares distributed among stock funds and
small shareholders.
The stock exploded by a factor of
six starting in 2006. No wonder – sales
are skyrocketing with breathtaking speed.
In 2001, the total production of the plant
was just 4,250 tons, but by 2006, it had
already climbed to 18,000 tons. Many
awards attest to the quality of the products; see “Prizewinner” on page 42. In the
past year, Vitaminka was elected one of
the three most successful companies in
Bosnia and Herzegovina.
A significant driver of growth has
been the segment of fruit drinks. Today,
Vitaminka realizes 45 percent of total sales
with these products. The sales of fruit
drinks are currently comprised of
* 50 percent fruit juices, nectars, and
syrups, and
* 50 percent fruit juice beverages.
The assortment of products marketed by Vitaminka through grocery stores and the restaurant trade is a broad one. For example:
* Apple, orange, and pineapple fruit
juices and tomato juice.
* The variety of nectars, syrups, and fruit
beverages include, for instance, strawberries, pears, blueberries, and peaches.
Apple juice and blueberry nectars are
the absolute top sellers.
No other producer in Bosnia and Herzegovina sells more fruit drinks as this model
company from Banja Luka. But the lead
over the competition will grow even more.
In 2007, the company wants to produce
15,000 tons of fruit drinks – just about
100 percent more than in the year previous – and by 2010, that should be 50,000
tons. “We’re expecting good growth rates
in Bosnia and Herzegovina,” explains Zarko
task+solution °
2
THUMBNAIL PORTRAIT:
VITAMINKA
1947 founded as company for processing
of wild berries
2002 privatized and converted into a
publicly traded corporation.
Dynamic growth ever since.
Production (in tons)
• Total
2001: 4,250
2006: 18,000
8,000 of which fruit drinks,
7,000 pickled products, the rest
preserves, sauces, and stewed fruits
2007 (p): 24,000
15,000 of which fruit drinks
•Fruit drinks
2006: 8,000
2007 (p): 15,000
2010 (p): 50,000
Sales
2006: €14 million
2010 (p): €50 million
p = projected
Special characteristics
The leading manufacturer of fruit drinks
in Bosnia and Herzegovina
Above Innopack Kisters TSP 35 tray shrink
packer: Bottles are wrapped in film and
Mikic, General Director of Vitaminka (per
capita consumption of fruit juices and nectars in the country 16 liters per year; Western Europe: 26 liters). In export, too, the
company wants to make significant progress.
Currently just about five percent of fruit
drinks go abroad, to Montenegro, Austria,
and to Switzerland. Soon, Vitaminka wants
to export a third of its production.
KHS TECHNOLOGY: “THE MERCEDES
OF PLANT ENGINEERING”
sent to the shrink tunnel.
Ambitious goals like that and the highest
expectations of product quality require
investment in innovative technology. Vitaminka has decided on KHS filling and
packaging technology with great certainty.
The reason for the move is explained by
Luka Sirovina, spokesperson for the Swiss
liter bottles receive body labels and cap
Lower left Innoket ROLAND 16/4: The 0.2tamper-evident labels.
Lower right Electronically controlled
Innofill DNRF long tube filler: Bottom-up
low-turbulence filling process ensures low
oxygen pickup in product.
40*41
2
Left A very special certificate for Zarko Mikiç,
PRIZEWINNER
General Director of Vitaminka: ’Manager of
the Year 2005‘ in Bosnia and Herzegovina.
* 2005: Director Zarko Mikic ’Manager
of the Year’ in Bosnia and
Herzegovina
* 2006: Vitaminka is one of the ’Three
most successful companies’ in
Bosnia and Herzegovina
* 2006: five gold medals at food trade
shows
5th station: Inspection with
Innocheck PROMECON 2000
+ Fill level and cap check + Channels out
flawed bottles.
main shareholder: “For us, KHS is the Mercedes of plant engineering.” And CEO Illija
Sirovina recently praised KHS technology
in an interview as a decisive success factor in our company.”
The output capacity of the new hot
filling system is 18,000 0.2-liter (restaurant) and 3,600 1.0-liter bottles (syrup)
per hour running in a single-shift. Multiple shifts would be no problem for this
system. And besides non-carbonated fruit
drinks, carbonated soft drinks can also be
filled later.
THE FOCUS: HIGHLIGHTS OF THE LINE
Here are the main features of the system
in a brief overview:
1st station: Innopal ASN
new glass depalletizer
+ Layer-wise depalletizing of glass bottle
pallets + Depalletizing robot with automatically adjustable head section + Pushbutton bottle size changeover + Pusher
system closed on four sides (providing
maximum safety) + All surfaces that come
into contact with glass bottles are coated
with plastic plates (gentle on containers,
avoids vibration and contact impulse noise)
+ Fully automatic handling robot integrated (gripping of inverted trays, slipsheets, empty pallets, transfer to magazine – above average efficiency).
2nd station: Clamping jaw rinser
+ Reliably removes dust and glass parti-
cles + Brings bottles up to temperature +
Steam tunnel automatically ensures specified temperature + Rinsing of carbonated
soft drink bottles exclusively with cold
water + Steam tunnel is conveyer segment.
3rd station: Innofill DNRF filling system
+ Pressureless hot filling of non-carbonated beverages (or pressure filling of carbonated products: selection of f illing
method at operator panel) + Fill level
method of filling fruit drinks with long
filling tubes (filling to rim, sterilization
of head room due to high product temperatures, uniform outfit) + Lifting mechanism presses bottle against filling valve +
Liquid valve opens with partial lift (product flows in at low speed and gently strikes
bottle bottom – important for pulp) + Complete opening of valve + Beginning of fast
filling phase + Bottom-up no-turbulence
filling process ensures low oxygen pickup
(for pressurized cold filling of carbonated
beverages, low CO2 consumption) + Smooth
liquid surfaces.
6th station: Innoket Roland
16/4 labeler
+ Two wet-glue labeling stations + 1-liter
bottles: Neck, shoulder, and back label +
0.2-liter bottles: back label plus cap tamperevident label (hot glue dot gives additional
adhesion for the tamper-evident label).
7th station: Innopack
Kisters TSP 35 packer
+ Tray shrink packer + With subsequent
manual palletizing + Later conversion to
palletizing system no problem.
Luka Sirovina and Zarko Mikic summarize together: “With this new line, KHS
has perfectly fulfilled all our needs and
requirements for an innovative technical
solution. It doesn’t get any better.” The
next peak is in sight.
Manfred Keller, Sales Manager Southeast Europe,
fi
INFOBOX
4th station: Two capping systems
+ Aluminum screw caps for 1.0-liter bottles (Innofill SV) + Twist-off capper for
0.2-liter bottles + General Director Mikic
comments on the new filler-capper block:
“The system offers us the greatest possible flexibility, leaving all options open to
us for the future and also ensuring the
best product quality.”
• WEBSITE www.vitaminka-kreis.com
• CONTACT
Manfred Keller, Sales Manager
Southeast Europe, KHS AG,
Bad Kreuznach
Tel:
+49 (671) 852-2655
E-mail: manfred.keller@khs.com
technology+innovation °
42*43
Quality seal label: Winzergenossenschaft
Sasbach always uses adhesive-pressure labels.
Innoket ROLAND 5/2 H offers maximum flexibility
The Versatile One
Winzergenossenschaft Sasbach provides an
excellent example for demonstrating the capabilities of the Innoket ROLAND 5 / 2 H labeler.
It can handle adhesive-pressure and wet glue
labels, paper and film labels, small and large
bottles, all coupled with unique benefits.
Winzergenossenschaft Sasbach, located in the Kaiserstuhl region of
Germany, is small, but first-rate. While the 46-member operations
only have a total of 107 hectares of vineyards, the quality is exceptional, as demonstrated by hundreds of gold medals received. Pinot
Noir is the most important wine variety. The winegrowers’ cooperative produces around 800,000 bottles of wine per year, with more
than 100 different dressing options. This means: Strict requirements
for the labeling equipment.
It therefore comes as no surprise that the partnership with
KHS has long since become tradition. The current KHS labeling
machine is the third such machine used by the winegrowers. Interesting: The winegrowers’ cooperative currently uses an Innoket ROLAND
5/2 H, offering a combination of adhesive-pressure and wet glue
labeling.
EQUIPMENT + PERFORMANCE
The system has two wet glue and two adhesive-pressure labeling stations and can process up to 5,000 bottles per hour. The line can handle bottle diameters between 50 and 110 millimeters and heights
between 80 and 310 millimeters. The machine design is vibrationfree, corrosion-resistant, and robust.
front and back labels are usually applied using the wet glue technique.
Simple handling. Stainless steel and durable plastic components
are easy to clean and ensure long service life, combined with high
machine availability. Pre-lubricated bearings reduce the cost and
effort involved in servicing.
Rapid changeover. Rapid format part changeover using quick-change
fasteners – no tools required.
OPTIONS + CONCLUSIONS
Adhesive-pressure labeling is not only possible with paper, but also
with film labels. Especially spectacular and particular eye-catching
– the no-label look. In any case, Winzergenossenschaft Sasbach
intends to continue its course of offering high-quality products. The
only yardsticks are quality and maximum customer satisfaction, not
least through versatility.
Jan-Wilhelm Brückel, Sales Manager,
Labeling Machines, KHS AG, Hamburg
fi
INFOBOX
BENEFITS + SPECIAL FEATURES
Adhesive-pressure or wet-glue labels. Different versions can be
used in any combination. Adhesive-pressure labeling provides capabilities for quick-as-a-flash reaction to the changeover required in
particular for personalized member brands produced at Sasbach in a
widest range of batch sizes. Gluing segment, label hopper, and gripper drum changing is a thing of the past – a significant cost-cutting
factor. The seal indicating the award presented by Baden’s winegrowers association is applied as an adhesive-pressure label, while
• WEBSITE www.sasbacher.de
• CONTACT
Jan-Wilhelm Brückel
Sales Manager, Labeling Machines, KHS AG, Hamburg
Tel:
+49 (40) 63703-37114
Cell phone: +49 (160) 9068-7087
E-mail:
karin.grage@khs.com
all Eventualities
A Dolly for
At the point of sale, compact, rolling transport systems are getting things rolling: dollies belong
in the store of the future. KHS provides a flexible system concept for these attention-getting
’mobilizing devices’ – for all eventualities.
The dolly – a transport system the size of
a quarter-pallet. The space-saving sales
displays on rollers have been winners in
stores in the Scandinavian countries for
years. Now they are beginning to conquer
markets worldwide. Because many advantages argue for using them:
* Dollies can carry anything
* Dollies can be used anywhere – in the
beverage industry as well as in food
and nonfood applications.
* Dollies can be loaded with alreadypacked goods – shrink packs, pad shrink
packs, tray shrink packs, and multipacks – anything goes.
* Dollies provide simple handling – store
personnel can easily roll them into
place.
* Dollies save time-consuming, boring
unpacking of goods onto shelves.
* Dollies put the focus on the product,
not the transport medium, due to their
low height
* Dollies keep the presentation area in
the store small.
tial. But one thing after the other. Looking at the dolly itself, you simply see a
steel carrier with two movable and two
fixed rollers. Inserted liners can be oriented entirely according to the product to
be transported. And a wide variety of plastic trays is equally as possible as well as
many different kinds of cardboard inserts.
HOW THE LINE
PROCESSES DOLLIES
A great advantage of returnable bottles
with dollies is that they can be returned
to the production plant loaded with empties. They can then be depalletized by the
system, including any inserted liners, and
then stacked. Dollies loaded with nonrefillables generally come back to the plant
stacked into one another. Two versions
are possible for both returnable and nonreturnable container dollies:
* Stacking on a Euro pallet
* Stacking of dollies into each other
without a pallet
Stacking on Euro pallets. If dollies are
KHS is now developing a system solution
especially designed for the dolly transport
system, which promises plenty of poten-
stacked on a Euro pallet, it is transported
by a pallet conveyor directly into a magazine where they remain for the time being.
A separate conveying segment takes the
carrier pallet out of the magazine. Removal
of individual dolly layers comes next, where
the system releases the bottom layer individually. Gripper fingers lift up and hold
the top dolly layers firmly in place.
Since a Euro pallet carries four dollies in each layer, discharging the dollies
onto two separate conveyor lanes is certainly practical. Here, two dollies in a row
go onto each conveying segment.
Stacking without pallets. If the dollies
are stacked together without carrier pallets, they are first carefully placed onto a
plastic mat table. The mat table ensures
gentle, safe transport of the dollies to the
magazine. In the magazine, the dollies
are destacked in the same way as in the
carrier pallet solution, and then transferred to the dolly conveyor. Whether one,
two, three, or even more conveying segments, all are modular in design, entirely
according to the customer’s requirements.
Variants needed later? No problem. Example: If a plant receives stacked dollies
instead of the carrier pallets they normally
get, the plastic mat conveying module as
well as the pusher can easily expanded.
44*45
The dolly is actually nothing more than an
easy-to-handle unit comprised of a steel
carrier with two fixed and two pivoting rollers.
*
*
*
*
*
*
*
*
And it just as simple to adapt the magazine to new requirements, to integrate
additional conveying segments into the
system, or to reduce the number of conveyor lanes.
Once the sensors of the conveyor system
have checked the roller positions of each
individual dolly, the dollies are grasped
by a hooked gripper head, lifted, turned,
and positioned as required.
Aligning dollies. The next step is to posi-
Conveying dollies. The design of the
tion the pivoting rollers on the dollies
identically. On the one hand, this makes
conveying easier, on the other it ensures
perfect palletizing, and finally, it is useful for smooth, reliable shipment to stores.
KHS conveying system has been thought
out down to the last detail:
* Transport of the dollies within each
conveyor lane using a clocked rail
* Integrated pickups push the dollies
gently through the entire conveying
process
The speed is adapted to that of the
upstream and downstream machines
Instead of pneumatic cylinders, the
KHS drive version works electrically,
with the advantages of greater flexibility in speed, gentle startup, and
gentle braking
Servo technology is possible
Hygienic to the least detail, a design
achieved by optimum guiding of the
rollers in a channel
Minimum roller wear
No maintenance needed,
Pallet conveying (instead of dollies)
is also possible
The dolly conveyor can easily be added
to existing pallet conveying systems
In a word: maximum flexibility is the
motto
Palletizing dollies. Usually, products are
placed onto four dollies at once (Euro pallet dimensions). However, it is also possible to palletize one or any number of
dollies. The only limit is the palletizing
system, which is oriented to the products
to be palletized, the slip-sheets to be
inserted, the desired output range, and
Left Usual: Positioning four dollies on a readied carrier
pallet. Right After transport of the dollies: Exact palletizing, generally of four dollies at a time.
the required number of dollies to be palletized. KHS offers both a variety of variants of two-column palletizing systems
(with modern KHS modular dry area design
with all its advantages) and also the option
of using articulated robotics.
DOLLIES AND ARTICULATED
ROBOTICS.
How flexible articulated robotics can be
is shown by a practical example. Task:
punching out inserted liners in addition
to folding and aligning them in a certain
way while loading with various products.
Solution: after the positioning of four dollies on the carrier pallet, a handling robot
grasps each inserted liner cut to Euro pallet dimensions and places it into a special
cutting facility. Another handling robot
is responsible for punching and placing
the cut inserted liners into a mobile centering system that folds the four cut inserted
liners in a special way and centers them
exactly on the supplied dollies. The rea-
son: This reliably prevents the product layers from slipping. The articulated robot
then places the desired product onto the
inserted liners.
Based on this example, it is clear
that even the most unusual palletizing
needs can be easily implemented. Depending on customer requirements, KHS experts
use handling robots for a variety of tasks.
The decisive point with the articulated
robot: Switching gripper heads ensures
that new types of packs can be processed
immediately. When palletizing tasks change,
the articulated robot can be given new
gripper heads and a handling robot can
be added.
The system is able to even palletize
dollies that are not already loaded on a
carrier pallet. They are either placed onto
a carrier pallet or processed individually.
Here, too, maximum flexibility is a given.
It is also possible to film-wrap each dolly
and place it in storage in addition to placing groups of four unwrapped or four film-
wrapped dollies onto the carrier pallet. In
either case, the carrier pallet loaded with
the dollies can also be film wrapped. It
must all be possible – because the future
belongs to the dolly.
Joachim Junghans, Manager of the Packing and
Palletizing Competence Center, KHS AG, Worms
fi
INFOBOX
• CONTACT
Joachim Junghans, Manager, Packing
and Palletizing Competence Center,
KHS AG, Worms
Tel: +49 (6247) 97-3467
E-mail: joachim.junghans@khs.com
46*47
Innofill DNRV: Fully automatic changeover to two bottle mouths and push-button CIP sanitizing.
World Innovation Innofill DNRV: fully automatic, flexible, hygienic
The fully automated Innofill DNRV combined filling system from KHS is a true masterpiece for
aseptically and conventionally processed non-alcoholic beverages. Forget manual intervention
during product, bottle type, or bottle mouth changeovers. Even CIP sanitizing runs virtually
automatically. This filler is one of a kind.
Alcohol-free in PET: This is the future, and
advanced technology plays a key role: the
new Innofill DNRV combination filler. With
this system, the KHS development engineers have once again set a new milestone
for pioneering beverage filling technology
worldwide. The Innofill DNRV filling system is able to process non-carbonated and
carbonated beverages – either aseptically
or conventionally – and handles all
changeovers without operator intervention.
The filling method is based on the
principle of volumetric filling with magnetic
inductive flowmetering. While the new system was specially developed for aseptic cold
filling, it also benefits beverage companies
using ultra-clean or conventional filling
techniques, because here too fully automatic changeover is particularly advantageous.
AUTOMATED: CHANGEOVER FROM
NORMAL PRESSURE TO COUNTERPRESSURE
Innofill DNRV combines two independent
filling valves in a single unit and can operate with both normal pressure as well as
counterpressure. Changeovers are automatic, which is particularly advantageous
for aseptic operation since product changeover
no longer requires operator intervention
in the isolator zone. This ensures higher
line availability and hygienically sound
aseptic operation.
NORMAL PRESSURE FILLING BASED
ON THE FREE-FLOW PRINCIPLE
Normal pressure filling is based on the filling principle used in the Innofill NV filler
from KHS. A neck ring guiding system transfers the PET bottles directly into the neck
ring holder positioned beneath the filling
valve. Sealing and pressing of the bottle
mouth against the filling element is no
longer required. In addition, the bottle
mouth no longer comes into contact with
valve components.
TRIPLE-CHAMBER COUNTERPRESSURE FILLING WITH ADDED BENEFITS
The counterpressure filling technique used
in the Innofill DNRV is based on the principle employed in the Innofill DRV. Aseptic operation is based on triple-chamber
counterpressure filling. This means that
the sterile gas used for pressurizing is not
circulated and continuously reused, but
discharged directly into the atmosphere via
a separate duct. This avoids gas flowing
back from filled bottles into the aseptic
process.
The bottle also passes to the neck ring
holder below the filling valve. In contrast
to normal pressure filling, the bottle is
now lifted pneumatically, followed by gastight pressing of the bottle mouth against
the filling valve. The valve seat of the freeflow filling system remains closed during
the whole counterpressure filling process.
In counterpressure filling, the path used
for the product in normal pressure filling
is used as the pressurization or return gas
path. Bottle pressurization with sterile
gas is followed by opening of valve seat
specially integrated for counterpressure
filling within the filling element. The product now enters the bottle over a swirler
and flows directly to the bottle walls at a
high rate of speed. The advantages of the
swirler are obvious: Avoidance of radiating elements protruding into the bottle,
and a high degree of flexibility for filling
a wide range of bottle shapes and sizes.
During the filling process, the return
gas escapes into the return gas channel
through two open gas cylinders, and from
there into the atmosphere. Once the filling level reaches the bottle neck, one of
the two gas cylinders closes, thereby reducing the return gas flow and the filling
speed. Once filling is complete, the return
gas path of the gas cylinder remains open.
Slight, controlled overpressure in the bottle neck facilitates gentle snifting. This
special procedure prevents excessive foaming and makes it possible to fill even highly
carbonated beverages at room temperatures.
In addition to triple-chamber pressurized filling, the Innofill DNRV can also
be used for single-chamber pressurized
filling, and if required for conventional
filling at the push of a button.
Conclusions: A highly flexible filling sys-
tem that meets all requirements of aseptic operation and the requirements relating to the product to be filled. Free-flow
filling is best for non-carbonated beverages, counterpressure filling with pressing of the bottle against the filling valve
is best for carbonated beverages.
AUTOMATED: BOTTLE
MOUTH CHANGEOVER
Different bottle mouth versions in the
aseptic process: no problem, because
Innofill DNRV always offers the option of
fully automatic switching between two dif-
ferent types of bottle mouth, and the bottle mouths don’t even have to be those
types normally used in the trade. Individual, company-specific mouth sizes can also
be used.
In the past bottle mouth changeovers
required time-consuming manual intervention in the filling valve area such as
replacing filling valve bases or neck ring
holders. The Innofill DNRV handles the
entire process at the push of a button.
technology+innovation ° World Innovation Innofill DNRV: Fully automatic, flexible, hygienic
48*49
Left Two independent filling valves in one unit: Filling with
normal pressure (left) or counterpressure (right).
Familiar benefits: increased line availability and maximum hygiene.
AUTOMATED: CIP SANITIZING
A further decisive benefit of the newly
developed KHS filling system: the Innofill
DNRV offers fully automatic CIP sanitizing. Again, CIP sanitizing begins at the
push of a button after automatic placement of the CIP rinsing plates.
AUTOMATED: CHANGEOVER
MECHANISM
A further special feature is a changeover
mechanism positioned centrally below the
filling valve that can automatically be
swiveled into three different positions as
required. Example: One position is reserved
for the neck ring holder for PET bottles with
size 28 bottle mouths, the second one for
the neck ring holder for size 38 bottle
mouths, the third one for the CIP plate.
The CIP plate is a flat metal plate
that moves in automatically to seal the
underside of the filling valve. The CIP
plate is specially designed to avoid deposits
of product residue. After the CIP process,
simple rinsing of the CIP plates is sufficient. The smooth surface design of the
filling system is a great advantage for CIP
sanitizing. All passages, from the tubular ring or central vessel to the filling
valves, are smooth-surfaced throughout
the Innofill DNRV. Aseptic membranes and
sealing technology are used inside the filling valves as well as in all other productconducting channels and passages. The
result is top hygiene and high microbiological safety coupled with minimized sanitizing periods.
AUTOMATED: CHANGEOVER
BETWEEN BOTTLE SIZES AND SHAPES
A wide range of bottle sizes and shapes,
ranging from 0.1-liter PET bottles to the
5.0-liter version, can be processed. The
changeover is carried out at the push of a
button.
Further Innofill DNRV characteristics:
* Filling capacity up to 60,000 bottles
per hour.
* Aseptic operation can be based on the
ACF process of dry or wet sterilization.
Depending
on the aseptic cold filling
*
process chosen, a wide range of upstream
and downstream systems can be integrated.
* In aseptic mode, the product is supplied from a central vessel, in conventional mode from a tubular ring vessel. Both tanks have no corners or
edges, resulting in maximum microbiological safety.
* Compatible with all other KHS rinsing
fi
*
*
systems (particularly important for
conventional filling).
Can be combined with a wide range of
KHS capping systems.
Application of servo technology. A key
advantage: automatic synchronization.
THE RESULT: VERSATILE
WORLD INNOVATION
The new Innofill DNRV filling system from
KHS is a versatile system that meets all
practical requirements of aseptic cold filling and other applications. Added to this:
No other filling system currently available
on the market of fers fully automatic
changeover of products, bottle and bottle mouth types, including automated CIP
sanitizing. Clearly a system with a promising future.
Ludwig Clüsserath, Manager, Process Engineering
Competence Center, KHS AG, Bad Kreuznach
Dieter-Rudolf Krulitsch, Process Engineering Competence Center, Filler/Rinser Technology Section,
INFOBOX
• CONTACT
Ludwig Clüsserath, Manager, Process Engineering Competence Center,
Tel: + 49 (671) 852-2501, E-mail: ludwig.cluesserath@khs.com
Dieter-Rudolf Krulitsch, Process Engineering Competence Center, Filler/Rinser
Technology Section, KHS AG, Bad Kreuznach , Tel: +49 (671) 852-2527
E-mail: dieter.krulitsch@khs.com
Double pre-evacuation during
the filling process: Significantly
reduces oxygen pickup in the
product.
Perfect upgrades for older machines and equipment
Fountain of Youth
Just because a system has been running for a long time, it doesn’t mean it is past its
prime. Quite often tried and tested equipment simply has to be equipped with modern components in order to ensure continued successful operation. One such example
is the bottling machine operated by Privatbrauerei Wittingen, the output capacity of
which was increased by 20 million bottles –virtually from one moment to the next.
Last year alone KHS has implemented more
than 700 equipment upgrades worldwide.
The tasks included improvement of the
production process, increasing line efficiency, making lines and individual machines
more user-friendly. Privatbrauerei Wittingen, one of the oldest private breweries
in Germany (established 1429), provides
a prime example for how this can be achieved
in close collaboration with KHS. The brewery had decided to upgrade the core component of its refillable glass bottle line, a
KHS Delta SVF filler made in 1982. Right
to this day, the private brewery is still in
the hands of the same family under current owner and managing director Christian Schulz-Hausbrandt.
THE SITUATION: LARGE PRODUCT
RANGE OFFERING TOP QUALITY
The brewery’s product portfolio includes
the classic Wittinger Pilsener, Wittinger
Premium, Wittinger Doppelbock, Stackmann’s Dunkel, Stackmann’s Alster, and
1429, a ’golden storage cellar beer’. Other
products include Aqua Sport table water
and Sport Orange and Sport Lemon soda
pops.
According to Mr Schulz-Hausbrandt,
all products meet top quality standards, as
demonstrated among other things by recent
awards. Examples include the gold medal
for Wittinger Premium and 1429 and the
silver medal for Wittinger Pilsener awarded
by DLG the German Agricultural Associa-
tion. The company boss says, “These awards
are the result of continuous quality control and our everlasting quest for further
quality improvement.”
THE AIM: MAINTAINING QUALITY
WHILE INCREASING CAPACITY
With the filler upgrade, the brewery also
had these aims in mind. Initially the team
consisting of KHS experts and brewery staff
assessed the current state of the refillable
glass bottle line. Based on this survey, KHS
made an offer based on the main requirements of the brewery, i.e. further improvement of quality and increase in filler capacity from 30,000 to 35,000 bottles per hour.
With two-shift operation and around 250
50*51
Conversion of the filler control system to Siemens S7, involving complete rewiring of the filler and
installation of a new control cabinet.
*
*
*
operating days per year, this equates to an
increase of no less than 20 million bottles.
*
*
THE UPGRADE: THREE-STEP
APPROACH TO ACHIEVING THE GOAL
KHS implemented the upgrade and optimization measures in three steps. The reason: The brewery expressed a preference
for three four-day downtime periods, rather
than a single 12-day period. The brewery
compensated the four-day downtime periods by moving shifts forward.
Step 3: Further improvement of
performance and quality
*
Step 1: General filler overhaul
*
*
*
Overhaul of the complete filler carousel
and all drive systems
New format part sets for the bottle types
used by the company
The result: Filling capacity increased by
2,000 bottles to 32,000 bottles per
hour. The aim of 35,000 bottles is closer.
Step 2: Improvement of
technological parameters
*
*
*
Conversion of the filler control system
from BBC Sigmatronic to Siemens S7,
including interface clarification
Integration of SVF filling method (double pre-evacuation) into the current filling system
Implementation of two new vacuum control systems – one electropneumatic and
one manual system
Associated open and close control plus
additional electrical components as required
Software adaptation: Redefine subdivided filler carousels for individual processing steps with adequate associated
reprogramming.
Integrate foaming unit (HPI device)
with proportional pressure control (no
entry of air in the bottle neck before
the crown cork is applied to the bottle)
Complete rewiring of the filler, involving more than 2,200 meters of cable
The result: Oxygen pickup in the product reduced significantly (from 0.42
milligrams of oxygen per liter down to
0.26). Substantial increase in beer quality and shelf life
*
*
*
*
Complete reinstallation of hardware components and conversion to electric beverage pressure control (previously pneumatic)
Integration of control element for pressure regulating valve in the new S7 control system (exact filling pressure and
CO2 control optimizes the filling characteristics, improves fill level precision,
saves CO2)
Include high pressure water rinsing and
filling control (for spraying out sections
contaminated with glass fragments)
Integration of detection systems consisting of proximity switches in the filling
system (to detect the location and the
filling valve where bottles are broken)
New turret for the crowner (for installation on the current, very robust capper
column). Advantages: Open machine
design, excellent accessibility, simple and
convenient cleaning. Lubricant-free capping elements ensure increased biolog-
*
*
ical safety and minimize maintenance
effort
Replacement of conveyors (gentle, uniform conveying of all glass bottles).
The overall result: Noticeably improved
quality while increasing the capacity by
20 million bottles per year.
Managing Director Christian Schulz-Hausbrandt is impressed, “With this upgrade
KHS met our requirements exactly as planned
and offered plenty of advice. We feel we’re
in excellent hands.” This is just one practical example of many. KHS is in the process
of establishing a catalog of the main conversion options for individual machines and
complete lines up to 30 years old. Naturally, in all cases the question of upgrading versus new investment should be examined carefully, because eventually any system will become too old to make an upgrade
viable.
Michael Beier, Manager, Spare Parts/Conversion
Technology Center, KHS AG, Dortmund
Alfred Krüger, Manager, Conversion Technology
Center, KHS AG, Dortmund
fi
INFOBOX
• CONTACT
Michael Beier, Manager, Spare
Parts/Conversion Technology Center,
KHS AG, Dortmund
Tel:
+49 (231) 569-1298
E-mail: michael.beier@khs.com
Alfred Krüger, Manager, Conversion
Technology Center, KHS AG, Dortmund
Tel:
+49 (231) 569-1492
E-mail: alfred.krueger@khs.com
New plant information system Innoline PMS by KHS perfects
transparency in bottling and packaging plants
The System of Systems
The innovative Plant Monitoring System (PMS) by KHS is now the state of the art – when it comes to
line efficiency, benchmarks, reporting, and cost control in beverage operations. Oriented towards
the latest Weihenstephan standard, PMS provides perfect communication and transparency for all
systems in the plant.
PMS in practice
ÇConnection optimal
ÇInformation comprehensive
ÇFlexibility maximal
ÇFuture built in
Transparency of all process flows: This is the mother of quality,
efficiency, and cost optimization. It sounds simple, but it’s not.
Because these goals can be achieved only when a variety of systems in production and the associated communication between
these levels is perfectly organized.
Enough of theory, now to the practical aspects: When filling and packaging with the new Plant Monitoring System (PMS),
KHS offers a production data acquisition process based on the
proven KHS Innoline AIS plant information system – and supporting fully the latest Weihenstephan standard (see “Keyword”, page
54).
systems, as long as the Weihenstephan standard is used for
connecting units).
* PMS works with open interfaces for data exchange to other
databases (for instance laboratory systems or logistics systems) and to other control systems (such as beverage production).
THE PRACTICAL USE OF PMS
The most important tasks (and implementations) of the Plant
Monitoring System for production planning are illustrated by the
following brief overview.
Task: Tracking filling batches
THE CHARACTERISTICS OF PMS
The Plant Monitoring System enables exact information exchange
between all systems, thus improving communication between people, machines, and devices. The special features at a glance:
* PMS supports the latest Weihenstephan standards for the coupling of machines and units in a plant.
* PMS creates optimum transparency using open interfaces to
existing – hierarchically higher – DP systems, such as MES (Management Execution System) or ERP (Enterprise Resource Planning).
* PMS is suitable for new and existing plants (even third-party
MES or ERP systems specify the filling orders. PMS imports the
orders via an open interface and groups them together into a filling batch. Direct creation of orders is also possible, if there is no
connection to a higher-level master system.
Each filling order and each filling batch must be traceable
– with the goal of achieving higher quality. This includes data
such as process values, fault events, limit value monitoring, manual interventions by the operating personnel. Running the system empty when changing over to other products is to be avoided.
This is why KHS uses the PMS system, based on the Weihenstephan
standard, to bring about a ’batch changeover on the fly’. This
52*53
ERP System
MES System
Logistics system
(raw materials and supplies)
Truck
Goods
receiving
Raw
materials
warehouse
Process control
system
PDA / LMSS
Beverage
production
Filling
Packing
Logistics system
(finished goods)
Shipping
Truck
Utilities
In addition to the optimum communication of PMS with ’like-ranked’ systems, the communication of PMS with a higher-level system
such as MES (Management Execution System) or ERP (Enterprise Resource Planning) is ensured.
means: the system breaks the line into different ’batch areas’.
When a batch change occurs, it is precisely registered when the
transition between the old batch and the new batch takes place
for each fixed sub-area. Exactly at the moment that the new batch
arrives at the defined sub-areas, the operator forwards this information to the PMS system by pressing a button. Machine operation integrates visualization and prior warning to the operator of
a prospective batch change.
The result is increased machine and line efficiency. In the Line
Monitoring System, this can be calculated according to various standards for both individual machines as well as the line as a whole.
These standards include DIN 8782, recommended by the Weihenstephan standard, as well as OPI (Overall Production Index) and
ODE (Overall Equipment Efficiency). PMS determines the efficiency
using formula objects, enabling simple adaptation of the calculation to the standard desired.
Task: Controlled calculation of efficiency
Task: Monitoring consumption data
No problem for the PMS system: the determination of the efficiency of individual machines. Here, too, the Weihenstephan
standard provides the right help, by precisely specifying machine
status and faults. The status model of OMAC (Open Modular Architecture Controls) is the starting point. Based on these definitions, the standard specifies an exact formula for calculating the
machine efficiency. Different interpretations are thus a thing of
the past. The PMS system can report the line and machine efficiency, either currently or over a given period of time.
The PMS system monitors both quality parameters within the system, such as Brix, oxygen content in the product, and so on, as
well as all consumption data from the line. And active intervention into events is possible. Because in addition to item data,
target and limit values can be defined for quality-relevant process
parameters. When the product type changes, PMS automatically
sends these parameters to the subordinate machine control systems. Here is an example that shows how ideal this is for quality
assurance. If the Brix content falls below a value specified in the
PMS system, it is feasible to activate an automatic lock in the filler.
Finally, the definition of limit values for media consumption also has an effect. For instance, if the water consumption
measured by the PMS system in the bottle washer or rinser exceeds
specified limits, this fact is automatically displayed thereby pro-
Task: Visualizing statuses
PMS makes it possible: the visualization of each system and machine
status on the screen – colored by system area, detailed records
quickly point out weak points, and the operator can react quickly.
Rejected bottles
Rejected crates
Depalletizer
Empty crate
check
Decrater
Bottle washer
New glass
depalletizer
Empty bottle
inspector
Filler capper
Pallet labeling
Crate washer
Fill level check
Pallet strapper
Crate magazine
Labeler laser
Crater
Label check
Palletizer
Full crate check
Bad bottles
Bad bottles
Rejected crates
The line is divided into different ’batch areas’. When a batch change occurs, the transition between the old batch and the new batch takes
place is exactly recorded for each fixed sub-area.
2
KEYWORD: WEIHENSTEPHAN STANDARD
The Weihenstephan standard is a set of requirements, which a work
group from industry, research, and users has worked out based on experience. KHS played a signficant role in this work.
viding immediate communication with the operating crew making quick reaction possible.
Task: Include coding
THE STANDARD PRIMARILY FOCUSES ON TWO GOALS:
1. Standardization of the coupling of machines and units to a production
data acquisition (PDA) system.
2. Definition of a minimum standard for the operation of these systems.
An important part of the standard is the definition of terms like filling
batch, filling order, and filling product. In this case, interface problems
between different systems in a single environment area are eliminated in
advance.
THE STANDARD CONSISTS OF FOUR PARTS:
Part one: exact specification of the physical connection for the regulation
of data exchange. Ethernet and TCP/IP are used.
Part two: exact description of the interfaces of machines and units to the
PDA system. Among other things, it is determined here which minimum
data each machine must supply for defined reports.
Part three: definition of minimum requirements for how the PDA system
must prepare the data available in reports.
Part four: includes instructions on how to validate and test the PDA system. There are predefined checklists, which can be used to verify whether
data displayed by the system also corresponds to the highest requirements
for accuracy.
Equally important is that in the PMS system, pallet and bottle coding units are incorporated with all their information (provided the
Weihenstephan standard is satisfied regarding the coupling of
units). This offers the maximum reliability and prevents the errors
from manually entered input right from the start.
Task: Support standard data points
The PMS system supports the full scope of standard data points
specified by the Weihenstephan standard. The main points:
* Operating mode: Manual, automatic, semiautomatic operation, or standstill. Program control of production startups
and stops, full production startups, begin and end of pauses,
determination of when sanitizing is necessary.
* Status: Based directly on the OMAC status.
* Faults: When a fault occurs that immediately leads to machine
standstill. A warning message does not immediately lead to
machine standstill. Besides display of the current fault status, historical data on fault messages can also be retrieved.
The same applies to warning messages.
* Analog values: All process values, e.g. temperature, pressure,
water, and power consumption (including access to historical
trends).
technology+innovation ° New plant information system PMS
*
*
*
*
*
*
*
Product information: Which bottle type, which type of packaging or pallet was or is in production at a given point in time.
Meter readings: How many bottles are or were underfilled,
for instance, and how many cases were damaged?
Media consumption: What amount of, say, CO2 or fresh water
does or did the system consume?
Signal exchange: A time graph makes it very easy to trace
which signals have been sent by the machines (incorrect behavior quickly apparent).
Process flows: What individual steps for certain programs are
carried out in what order?
Inspection tests: For perfect quality monitoring. Testing of
the inspection system using test bottles. Automatic recording
allows access at any time to corresponding data.
Filler batches: On-the-fly batch change ensures exact assignment of products to individual filler batches. PMS is able to
recombine the data recorded at the individual machines at different times for the batch reports fully automatically. Thus, the
system shows all data related to a filler batch in the corresponding batch report.
PMS IS CUSTOMIZED FOR EACH CUSTOMER
The KHS PMS system is available in different versions and adapted
completely to customer requirements. The general rule: The PMS
system can always be extended. The smallest imaginable configuration is PMS Basic. Here, only the filler area is integrated into the
system. PMS Midi: all main machines in a line are connected. PMS
Pro: the data from several filling lines can be integrated.
54*55
process control system, warehouse management and forklift control system, laboratory system. This is followed by scheduling and
in-house testing by KHS. The next step: delivery of the PMS system and training of the operating personnel. Everything carried
out systematically.
Wolfgang Heßelmann, Manager, Plant Information Systems,
KHS AG, DortmundKHS AG, Dortmund
2
PMS PLUS: MOBILE SCANNER
This new KHS development completes the PMS unit: a mobile
scanner. It brings additional advantages to quality assurance
and cost control. Purpose: To scan raw materials and supplies.
Benefits:
* After initialization, the scanning system is equipped for any
task.
* Extensive programming of the scanner is unnecessary.
* Whether caps, labels, or raw materials – only one scanner is
needed to scan them all.
* The PMS server automatically loads all required data for newly
used materials in a line to the scanner – without additional programming of the scanner.
* The scanner is ultimately even capable of providing information
about the line including fault messages, which can be displayed
directly by the scanner.
MULTILINGUAL DESIGN
As an internationally active company, KHS offers the PMS system
with multilingual capabilities. Each user may select the desired language.
If a company decides on the PMS system, KHS first ensures
that the individual machines are physically connected. Next is the
declaration of interfaces to other existing systems, such as the
fi
INFOBOX
• CONTACT
Wolfgang Heßelmann, Manager, Plant Information
Systems, KHS AG, Dortmund
Tel:
+49 (231) 569-1612
E-mail: wolfgang.hesselmann@khs.com
EXAMPLE: RECEIVING NEW CAPS
* Cap storage location is identified by an EAN code.
* The cap storage location is scanned before the EAN code of a
box of caps is scanned.
* The scanner automatically loads the right mask for the material in the PMS system.
* The operator scans the EAN code on the carton.
* The system checks whether the scanned cap material is permissible.
* If permissible, the caps are introduced to the production process
(illegible EAN codes are entered into the scanning system manually).
* Storage under the corresponding batch number.
The result: which caps were supplied to which batch is traceable at
all times. The scanning system is also capable of exact batch control, which can be used to make conclusions regarding quality and
costs.
What is Viscosity?
Any filling process involving beverages or cosmetics, for
example, is characterized by two key parameters: the shear
rate during filling, and the physical properties of the fluid.
Sir Isaac Newton laid the foundation for our understanding
of viscosity.
56*57
Viscosity
x
Velocity v
Dilatant
Plate B
Bingham
Fluid
Newton
Pseudoplastic
Plate A
y
Shear rate
Shearing inside a fluid between two plates (schematic)
Typification of viscous substances in a viscosity diagram
The term rheology refers to the flowing and deformation behavior of matter, i.e. the natural laws describing the flow of liquids,
solids, and colloidal systems under the influence of external forces.
The flow characteristics of substances depend on their physical and
chemical characteristics. It is determined by the shape and configuration of the molecules, the concentration, the temperature,
and cross-linking. The following parameters characterize the rheological properties of a substance:
* viscosity or apparent viscosity ,
* shear stress , and
* shear rate dv/dy (velocity gradient of velocity v in y-direction).
Dividing the dynamic viscosity by the density of a liquid results in
the kinematic viscosity
Dynamic viscosity is measured in Pa·s and usually determined with
the aid of a rotational viscometer. Another unit of measurement
for viscosity used to be poise (or centipoise), with:
1 Ns/m2 = 1 Pa·s = 10 Poise and 1 Centipoise = 1 cP = 10-3 Ns/m2
Viscosity is a key rheological term relating to internal friction.
It describes the resistance (internal friction) developed by a fluid
during relative movements of two adjacent layers. This flow resistance not only occurs in liquids, but also in gases and even solids.
In simplified terms, the effect of internal friction can be pictured
as the movement of two interlocked horizontal molecular layers.
During the movement molecules glide past each other, with a certain force required to overcome the interlocking. Viscosity defines
the relation between this force and the properties of the fluid.
The greater the viscosity, the more viscous (i.e. less flowable) the
fluid, since the bond between the particles is stronger, making
them less mobile.
In 1687, Sir Isaac Newton described the dynamic viscosas a proportionality constant between shear stress and
ity
shear rate dv/dy (flow velocity gradient):
=
dv/dy
NEWTONIAN FLUIDS
Fluids with a linear relationship between shear stress and shear rate
dv/dy are referred to as Newtonian fluids. In this case, the viscosity at constant temperature and constant pressure is a material
constant. The classic example is water.
NON-NEWTONIAN FLUIDS
In non-Newtonian fluids, the viscosity changes as a function of the
shear rate. In this case, viscosity is not a material constant, and
the fluid does not follow the elementary Newtonian friction law.
The reason for this behavior is a reduction or increase in the
interactions within fluid due to modification of the microscopic
structure. Dispersed or suspended particles tend to deform or
rearrange themselves.
STRUCTURAL VISCOSITY (PSEUDOPLASTIC FLUID)
The effect of falling viscosity with increasing shear forces within a
2
NON-NEWTONIAN FLOW CHARACTERISTICS
Flow characteristics
Example
Pseudoplastic
No-drip wall paint, blood
Thixotropic
Yogurt, ketchup
Dilatant
Gelatin pudding, pasta dough
Rheopectic
Dry sand
Bingham
Mayonnaise, Vaseline
Casson
Chocolate
fluid is referred to as structural viscosity. The stronger the shearing effect, the less viscous the fluid. This is described as ’shearthinning’.
Examples:
This property is utilized in no-drip wall paint. Blood is also pseudoplastic: Under the influence of strong shear forces, the red blood
cells tend to become oblong, making the blood flow easier through
small blood vessels.
Thixotropy
While a pseudoplastic fluid only has a lower viscosity under the
influence of shearing, in a thixotropic fluid the reduced viscosity is
retained after shearing and is only built up again slowly. The structure of the fluid changes, leading to reduced interactions between
the particles. These structural changes are not reversed immediately after any exposure to shear force. Examples: yogurt and
ketchup.
Dilatancy
The effect of increasing viscosity with increasing shear rate dv/dy
is referred to as dilatancy. This behavior is observed in tightly
packed, dispersed substances. Example: Starch solutions (gelatin
pudding, pasta dough). If one slowly immerses a flat hand, the
solution appears almost liquid. In contrast, the hand rebounds if
the solution is hit hard, i.e. the solution almost behaves like a solid.
Rheopexy
As in dilatancy, increased viscosity is retained after shearing.
Rheopexy is a rare phenomenon, as demonstrated by the following
experiment.
Dry sand interlocks in the presence of high shear forces and
retains its new shape: If a rod is placed in a cylindrical container,
the container is then filled with dry sand and compacted and the
rod is lifted, the sand is sheared leading to interlocking of the
grains, and the whole container moves upwards. After some time
the grains of sand relax and can glide past each other and the rod
is released.
Plastic fluids (Bingham or Casson fluid)
Fluids that start flowing only above a certain level of shear stress
are referred to as plastic fluids. Below the yield point, the substance behaves like a solid. This effect occurs in dispersed systems
that interact strongly via van der Waals forces, hydrogen bonding,
and dipole-dipole forces.
Plastic substances are classified as follows, based on their
flow characteristics:
* Bingham substance: These are fluids with classic (Newtonian) flow behavior once the yield point is overcome. Examples:
Mayonnaise and Vaseline.
* Flow characteristics according to Casson: These are substances where shear rate and shear stress are not proportional
once the yield point is overcome. Example: Chocolate.
CONCLUSIONS
Viscosity values always have to be judged against the background
of the flow characteristics of the respective substance. Viscosity
measurements therefore always involve a series of measurements
with different shear rates.
In the beverage and cosmetics industries a wide range of
substances with non-Newtonian flow characteristics are encountered. All filling processes therefore have to take into account the
shear rate during the respective filling process and the respective
fluid characteristics. In practice, this may mean that a higher flow
rate not necessarily leads to a faster filling process, if the substance
to be filled is a dilatant fluid, for example.
Organic components (pulps) and thickening agents have
complex molecular structures with different flow characteristics
that may lead to very individual viscosity curves.
Elke Vetter, Laboratory and Technology Center, KHS AG, Bad Kreuznach
fi
INFOBOX
• CONTACT
Elke Vetter, Laboratory and Technology Center,
Tel: +49 (671) 852-2760
E-mail: elke.vetter@khs.com
Guest at KHS °
58*59
Left World-famous: Prague’s historic old town. Below For
the romantic: Through the past with the horse-drawn carriage.
Welcome to
Prague
What is it that makes this town magical? Is it the many sights, is it
the architecture, the more than one thousand years of history, the
excellent beer, the old cafes and restaurants, the hearty meals, the
leisurely flowing river, the islands, the hills, the old town, the people, the tourists from all over the world, the modern shopping
palaces, the old jazz bars, or the hip discotheques? Quite honestly,
there is no answer. Prague’s magic can be found in all of these.
More or less – and also as a candidate for the summer Olympic Games.
The capital of the modern Czech Republic, vaunted as the
Golden City or the City of 100 Spires, presents itself to travelers with
world-famous squares and palaces. And yet you must look a little
to one side, go around the corner, in equal measure to discover a
little more of Prague as a supplement, perhaps a little bit as the
locals experience the city – only then will you have the whole of
Prague in your heart.
To start with the famous sights, let us take Prague Castle,
the most visited tourist attraction in the city – and rightly so. But
after seeing the really imposing cathedral and the ancient king’s
palace, who of the many guests wants to visit the vast gardens in
the castle grounds? From here, you have one of the most beautiful views over everything that Prague stands for. And another tip
for sports enthusiasts: from the spire of the cathedral, you will
finally have the city at your feet.
It’s no different with the restaurants. Of course, the beer
temple U Fleků, and the most beautiful cafe in town, the Kavárna
located in the House of Representatives, should also be on the visitor’s itinerary. And also the Evropa, a wonderful youth-style cafe
in that lively meeting place, Wenceslas Square, has something special. Has time stood still here? Or quite simply the Bar Konirna
(Annenska 11, southeast of the Charles Bridge), a cellar-like tavern with a touch of genuine suburban pub, in which hostess Petra
Koppová serves the almost exclusively locals – resolutely but not
ungracefully. This is where people know each other; this is where
Prague is completely Prague. On the other side of the Vltava River
is wine bar U Mecenáše (Malostranské nám), steeped in tradition,
with its 17th century interior, and before that, once the local haunt
of the executioners of the medieval city.
The heart of Prague is and will of course continue to be the
old part of town. Life pulses in winding lanes and alleys where
shops, restaurants, cafes, and bars now occupy former patrician
houses. Before going back to your hotel, take a walk over the stone
Charles Bridge, which King Charles IV built more than six centuries
ago to connect the two banks of the Vltava. You can imagine that,
when night has fallen, the young people of the world would get
together here.
A little later, sometime after midnight, it might be worth
your while to detour into a pleasant nightspot or disco considering
that, with more than 160 liters per capita per year, the Czech Republic is world champion in beer drinking. Now to Radost in the new
town, formerly an insider’s tip, today rock spectacle in the old cinema basement. It is closer to go to the Klub Lávka directly on the
bank of the Vltava … that is, for those who want to see and be seen.
Or to U Mustků in Wenceslas Square. Here, late-night revelers have
a fantastic view over nighttime Prague. The magic of this town …
it must be out there somewhere. “Na zdravi” –
Welcome to Prague.
The KHS team and Lubomir Neubauer,
Manager of the KHS Branch Office in the Czech Republic
30 1992-01-986/2 0907 GW
Adresses
KHS AG
Juchostrasse 20
D-44143 Dortmund, Germany
Tel
+49 (231) 569-0
Fax
+49 (231) 569-1541
Planiger Strasse 139-147
D-55543 Bad Kreuznach, Germany
Tel
+49 (671) 852-0
Fax
+49 (671) 852-2411
Enzingerstrasse 139
D-67551 Worms, Germany
Tel
+49 (6247) 97-0
Fax
+49 (6247) 97-3215
Ruwoldtweg 14
D-22309 Hamburg, Germany
Tel
+49 (40) 63703-37100
Fax
+49 (40) 63703-37150
Boschstrasse 1-3
D-47533 Kleve, Germany
Tel
+49 (2821) 503-0
Fax
+49 (2821) 26110
Am Kirchfeld 3
D-34454 Bad Arolsen, Germany
Tel
+49 (5691) 8909-0
Fax
+49 (5691) 8909-15
Kapellenstrasse 47-49
D-65830 Kriftel, Germany
Tel
+49 (6192) 491-0
Fax
+49 (6192) 491-144
Industriegebiet Scheid 16
D-56651 Niederzissen, Germany
Tel
+49 (2636) 9746-0
Fax
+49 (2636) 9746-45
E-mail: info@khs.com
Masthead
KHS UK LTD.
Unit 6 Monkspath Business Park,
Highlands Road
Shirley Solihull, Great Britain
West Midlands B 90 4NY
Tel
+44 (121) 713-6900
Fax
+44 (121) 745-6935
E-mail: info@khs.com
KHS USA, INC.
880 Bahcall Court
Waukesha, WI 53186, U.S.A.
Tel
+1 (262) 797-7200
Fax
+1 (262) 797-0025
E-mail: mike.brancato@khs.com
5501 N. Washington Blvd.
Sarasota, FL 34243, U.S.A.
Tel
+1 (941) 359-4000
Fax
+1 (941) 359-4043
E-mail: randy.uebler@khs.com
KHS PACIFIC PTY. LTD.
P.O. Box 378
1-3 Freight Road
Tullamarine, Vic. 3043, Australia
Tel
+61 (393) 35-1211
Fax
+61 (393) 35-1331
E-mail: info@khspacific.com.au
KHS ASIA PTE. LTD.
25 International Business Park
# 3-15/19 German Centre
Singapore 609916
Tel
+65 6560-9313
Fax
+65 6560-9910
E-mail: info@khsasia.com
KHS MACHINERY PVT. LTD.
15, Madhuban, Nr. Madalpur Underbridge
Ellisbridge, Ahmedabad - 380 006, India
Tel
+91 (79) 2644-0331
Fax
+91 (79) 2644-5146
E-mail: khs@khsindia.com
KHS worldwide: You will find further addresses and contacts at
www.khs.com
PUBLISHER
KHS AG, Dortmund
EDITORS
Friederike Arndt, Maternus Gemmel, Manfred Rückstein,
jj-media, Cologne
GRAPHIC
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Yvonne Voss
CONTRIBUTIONS
Michael Beier, Jan-Wilhelm Brückel, Joachim Brzoska,
Ludwig Clüsserath, Ludmila Enke, Thomas Ess, Wolfgang
Heßelmann, Joachim Junghans, Manfred Keller, DieterRudolf Krulitsch, Alfred Krüger, Jörg A. Lauer, Lubomir
Neubauer, Jaroslaw Niebisch, Werner Oster, Elke Vetter
TRANSLATIONS
Fachübersetzungen CP MacKusick
PHOTOS/ILLUSTRATIONS
Friederike Arndt, Carlsberg Deutschland GmbH, Carson
Ganci/Design Pics/Corbis, Hans Gronauer, Tobias Gursch,
Burkhardt Hellwig, Ingo Jezierski/Corbis, Kofola Holding
a. s., Kulmbacher Brauerei AG, Mauritius, Frank Reinhold,
shotshop.com, Unilever Deutschland GmbH, Larry
Williams/Corbis
KHS journal offers young students and graduates of the
University of Applied Sciences in Dortmund and Münster
the opportunity to put their photography talents into
practice.
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.

07.388 KHS Journal 02_07_e

Transcription

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