Khs Competence 02-2011 Englisch Einzeln

8/10/2019 Khs Competence 02-2011 Englisch Einzeln

1/80

Innovation

A deluxe shrink packer:

quanum leap

Solutions for Water Bottling Plants

Silver Springs:

bring on he waer!

Innovation

Asepic linear filler:

maximum sandards

02.2011

22 40 60

Innovaive Filling PlaformFor Glass Botles

NEW ERA


2/80

Our objecive:Service and echnology leadership.

Executive Management Board of KHS GmbH

Prof. Dr.-Ing. Matthias NiemeyerAnke Fischer

Prof. E.h. Dr.-Ing. Johann Grabenweger

Marc Hartmann

Ediorial


3/80

Voltaire coined the phrase: The best is the enemy of the good.

If we transfer this to KHS, we have started our journey to get to the best. Fit4Future is the

name of our eleven-component program that we use systematically to walk this challenging

path and to boost the already existing mood of awakening in the company.

What are the key points that show you our customers and partners that we have start-

ed our journey successfully?

With the goal of operational excellence, we will work even closer with you, improve the

pace in execution, and will respond flexibly to all inquiries and requests. Our declared goal isthe technological and service leadership combined with profitable growth. In this regard, we

can continue to count on the support from our parent company, Salzgitter AG, for the consist-

ent development of our company and our product portfolio.

Fit4Future means for us, first and foremost, lean processes and reduction of complexity while at

the same time growing physically closer together: The Keg Technology will move from Kriftel toBad Kreuznach, our second largest location. Aside from the excellent infrastructure, the plant

in Bad Kreuznach offers the possibility to better compensate for peaks in demands; in addition,

sufficient areas for extension to accommodate further growth are available.

We can only become better if we query the conventional, change the existing and find new, in-

novative solutions for developing and improving processes and products. Innovations are needed.

How successful innovation management works is a topic the editors have discussed in

depth with Dr. Tobias Mller-Prothmann. His credo: Companies must tackle innovations very

systematically. You can see and experience the result of our own innovation management in a

great number of new products that we are currently launching.

So what KHS innovations can we present to you in this issue of competence? The aseptic

linear filling machines Innosept ABF 611 and 711, the compact Innokeg Till CombiKeg, the new

filling machine generation Innofill Glass in consistent hygienic design, and a packaging processfor completely closed heat-shrink packs are some of the most important product innovations

that KHS is launching in 2011.

As you can see, KHS is highly innovative.

Enjoy reading!

Operaional excellence

hrough innovaive and inelligen soluions.

Ladies and Genlemen:

Kind regards,

Prof. Dr.-Ing. Matthias Niemeyer

compeence 02.2011 /


4/80

Innovaions ha give ourcusomers more

Main opic Page 1245

Inerview

06Growing With Innovations

Dr Tobias Mller-Prothmann talks about

the importance of systematic innovation

management for companies

KHS subjecs is producs and sysems o a coninuous

process o improvemen. In his ediion o KHScompeencehe company will be presening a number

o differen innovaive echnologies and urher

developmens. In all o hese KHS has consisenly

ocused on he benefi o he cusomer, hus achieving

susained produc improvemens and hereore also

cos and compeiive advanages.

Innovaion

12Topic Overview: Innovations In Focus

14New Era

KHS presents the innovative filler platform

for glass bottles

22Maximum Standards

New generation of aseptic linear fillers

from KHS for still beverages and otherliquid products

28Short Routes

New, resource-saving cleaning system from

KHS with a 15% investment benefit

06

Conens


5/80

Innovaion

30A Real All-Rounder

KHS has developed a space-saving keg line

for medium-sized businesses

34Tempo, Tempo, Tempo

Preparing and palletizing shrink packs with

KHS technology

38The Space Saver

The Innoket 360 S labeler extends the

KHS roll-fed range

40Quantum Leap

Innopack Kisters SP shrink packer

developed even further: a deluxe

shrink packer

Service

46New System New Prices

Over half of the prices for KHS spare parts

now reduced

48Keeping On Running

At the Karlsberg brewery a joint concept

provides systematic service

On he Spo

53HotFill+ Efficient, Sustainable, Successful

Interview with Rajendra Gursahaney,

senior director of engineering,

Pepsi Beverages Company, the father

of the HotFill+ process

Marke Repor56Underberg / Coca-Cola FEMSA /ASTBeverage / Distell / Cobega / La Casera

Soluions or Secors

60Bring On The Water!

The first 72,000-capacity InnoPET BloFill

in operation at the Silver Springs BottledWater Company

64Focus on Quality

Kompania Piwowarska invests in its third

100,000-cph can line from KHS

66Fifth Can Filler for CCE in the UK

Coca-Cola Enterprises (CCE) Great Britain

installs its fifth high-performance can filler

from KHS

Soluions or Secors

67Can Power

Frances largest family-owned brewery,

Meteor, works with a KHS large-can line

Special

70Hidden ChampionsHow smaller players conquer world markets

In-house News

76KHS at Brau Beviale 2011

Technology. Performance. Reliability.

78

News from KHSECOPROFIT at KHS Corpoplast / KHS Asia

moves to new offices / FOX AWARD 2011

GOLD for KHS competence / Company runs

for charity / KHS website for smartphones

79KHS competence

Publishers information and addresses

22 60 67

compeence 02.2011 /


6/80

Inerview


7/80

Dr Tobias Mller-Prohmann alks abou he imporanceo sysemaic innovaion managemen or companies.

/

Regardless o wheher companies generae srong sales or have o

wach coss careully when hings aren oing so well, he sysemaic

managemen o innovaions is a risk o being negleced.

This is a aal, creeping process. KHS compeencealked o

Tobias Mller-Prohmann, head o innovaion managemen a

Pumacy Technologies AG, abou he appropriae handling o innovaions.

GROWING

WITHINNOVATIONS

compeence 02.2011 /


8/80

Enrepreneurs have o deal wihinnovaions very sysemaically.The focus mus always be on he

employees.

Whats the main motivation for employeesto contribute ideas?

The key is to inspire passion in each individual and let them

participate in success. This doesnt always have to be in the

form of money. Showing appreciation for ideas and prais-

ing creative staff in front of the whole team can have a tre-

mendous effect.

How does a manager steer such a process?

He encourages individuals to come up with new ideas, fil-

ters out good approaches as quickly as possible, and avoids

getting bogged down in the process. Its better to reject

an idea early if the prospects of success are questionable.Either way, staff should be praised for their suggestions.

How do bosses encourage their executives to

become catalysts for innovations?

All they need to do really is talk about success stories. A clas-

sic example is the attempt to develop a superglue by a 3M

employee, which turned out to have poor adhesion. The first

product to emerge from this was a flop and was stopped

by the boardroom before another colleague continued the

development because his bookmarks kept falling out of his

music in the church choir. Today we all have the result of the

KHS Competence: Dr Mller-Prothmann,its a long way from a brilliant idea to an innovative

product that prevails on the market.

When is innovation management successful?

Dr Mller-Prothmann: Innovation management itself

doesnt generate new ideas, and it doesnt market new

technologies. Rather, it supports the whole process from

the early phase of idea generation to implementation to

ensure that in the end a new product or service will pre-

vail on the market. This, then, is the success.

Where do the enemies of innovations lurk in companies?

When a company is doing well, everyone focuses ongrowth, while in bad times the focus is on costs. Systematic

innovation management can easily be neglected.

Inventiveness cannot be ordered from above.

What has to change in peoples heads?

Ultimately the key is openness. Executives have to be open

for internal ideas as well as external impulses. Within com-

panies its important to have lively exchanges between de-

partments. Whats needed externally is good communica-

tion with research institutes and customers. In addition,

employees need sufficient freedom.

Inerview


9/80

Dr Tobias Mller-Prothmannis head of innovation management at Pumacy Technologies AG,

a leading systems provider for knowledge, innovation,

and process management. The 37-year-old studied sociology

and economics in Heidelberg, Germany, and did a PhD in

communication studies in Berlin, Germany. He is the author of

the book Innovationsmanagement: Strategien, Methoden und

Werkzeuge fr systematische Innovationsprozesse(Innovation

Management: Strategies, Methods, and Tools for Systematic

Innovation Processes), published by Carl Hanser.

For example?

Many aircraft now have an upwards facing angle piece at

the end of the wings. These winglets reduce turbulence

at the wing tips, thereby reducing kerosene consumption

significantly. Ultimately, the inspiration for development

engineers came from the pinion feathers of raptors.

What function do skeptics have in creativity workshops?

Critics are important. After all, they may be right and can

help by pointing out risks at an early stage. On the other

hand, objections may be rebutted. This helps to sharpen

the argumentation, and everyone will come on board ifthey feel they are being taken seriously.

How independent should the individual teams be?

Today, companies tend to establish quite independent in-

novation centers with small teams. These innovation cells

have their own budgets and operate very autonomously,

although they are in contact with other departments in

order to allow communication when problems occur. The

team can market its innovations to the associated busi-

ness areas in order to attract further sponsorship from the

respective management, or to hand over innovative ap-

proaches for further development.

innovation with apparently inferior adhesion on our desks

in the form of yellow Post-it notes. Such stories inspire.

Whats the point of bosses encouraging their teams

to let their minds wander as part of workshops?

Most ideas dont spring to mind at the workplace. Rather,

they do so in the shower or when jogging. Nevertheless,

creativity workshops during which a team has a clear task

can be very useful. For example, a team could be asked to

develop 100 new ideas on topic X or solve a certain prob-

lem Y for the company. For such gatherings it can be help-

ful to bring in an experienced external moderator, whocan point out new perspectives.

How can vague brainstorming be turned into

concentrated creativity?

Initially its important to think outside the box and ignore

possible internal constraints. For example, a question for a

round of engineers might be: What can we learn from the

animal world? Because nature has come up with systems

that have been tried and tested over long periods. Those

who look carefully will see blueprints for pioneering inno-

vations. In other words, whats known as bionics is the art

of looking for solutions to technical problems in biology.

The inerviewee

compeence 02.2011 /


10/80

Showing appreciaion for ideas

and praising creaive saff in

fron of he whole eam can have

a remendous effec.

Many new products fail after generating immense costs.

Why is that?

A much-quoted study found that a successful product is

based on 3,000 raw ideas. In many cases theres a lack of

systematic support for the process and a lack of clear deci-

sions. Its important to allow freedom in the initial phase

and then decide whether or not to pursue the idea. The

decision-makers have to focus on profitable innovations.

During the prototype production phase the number of

ideas that fail should be smaller.

What are the milestones during the developmentof an idea into a marketable innovation?

Initially trends are scrutinized, and ideas are checked and

assessed. A detailed system concept should be prepared

during the pre-development phase. A prototype has to

demonstrate how the innovation can be implemented. Fi-

nally, the model is fine-tuned until it is ready for series pro-

duction. In the software industry such a process can take

two months, in the automotive industry five to ten years,

and in the aerospace industry two to three decades.

Financial staying power is another important factor.

How can medium-sized companies avoid running out ofsteam half way through the process?

Naturally much will depend on the required means and

the time frame. The central question is: When will the in-

novation find acceptance on the market and achieve a

return? The entrepreneur may obtain credit from fami-

ly members, acquaintances, or his bank. He can take ad-

vantage of public grants, involve large customers in the

financing, or win over a venture capitalist for his idea.

All these options should be considered early on. In many

How much influence should marketing be allowed

to have when it comes to the prospects of success

of a product idea?

Sales and marketing experts from the company should be

integrated from the outset, because they know how the

products have to be designed in order to go down well

with customers.

How helpful is it to include scientific institutes in the in-

novation processes?

This often works well, particularly in the early design

phase, and is today common practice in biotechnology,for example.

And how about integrating large customers?

They should definitely be involved from the outset. Be-

cause they know exactly what they need and can often

provide valuable inspiration for new ideas.

Can you give an example of a company

with an excellent innovation culture?

Weve already mentioned the technology company 3M

who are a good example. They have a long tradition in this

regard. Good ideas are not only rewarded by monetaryincentives, but also by appreciation. The company sells

50,000 products from Post-its to stethoscopes. The mar-

ket share of new products that are less than five years old

is more than a third. We can also learn a lot from young-

er technology companies such as Google. Google intro-

duced the so-called 70/20/10 system for all employees at

an early stage. It means that 70% of the work time should

be spent on core tasks, 20% on collaboration with other

teams, and 10% on an employees own ideas.

Inerview


11/80

The milesonesin successulinnovaionDr Tobias Mller-Prothmann on important aspects

for systematic innovation management.

The inerviewer was Rudol Kahlen

A he sar here is a realizaion:Companies have a clear need or acion when i comeso he managemen o innovaions, even i he menalsrain is sill small.

This is ollowed by analysis:Where does he company sand? How innovaive is i?

The nex sage involves ocusing on heinrasrucure or innovaions:

How sysemaic can ideas be realized?

Thepossible inererence acors,eiher inernal,echnical, or exernal, hen have o be idenified.

In response, he relevan adjusmen screwshaveo be urned: I, or example, he knowledge exchangebeween he deparmens is no working, his shouldbe correced.

The nex sep is o ormulae a sraegyand o speciyhe required acions.

And finally, even i his may sound obvious,he specified acions have o be consisenlyimplemened.

cases the individual phases of an innovative development

require several financing rounds.

Finally, lets have a look at process innovations in

companies themselves. How can ideas be called up in

order to make operational processes more efficient?

Ideas should be called up where they emerge. On the plant

floor a small mailbox may be all that is needed, or a special

folder on the company server.

Is this where staff hand in good ideas?

Definitely, if appropriate incentives are provided. As anexample, the person with the idea could receive 25% of

the savings that his suggestion makes in the first year. This

works, but not on its own. As already mentioned, whats

also needed is appreciation that goes beyond monetary

incentives.

How should bosses deal with the (understandable)

concern that individual members of staff could make

themselves redundant with a clever idea?

This may indeed be a worry here and there, but the man-

agement can easily rebut it. They simply have to make it

clear that redundancies are not on the agenda perhapsmerely relocation to another business area.

In summary, what are the three main points which

ensure that companies achieve significant growth

with compelling innovations?

Innovations aim to secure the companys future. The en-

vironment and the competition change. In the best case

the company will also grow. The crux of the matter is that

entrepreneurs have to deal with innovations very system-

atically. The focus must always be on staff, and innovation

management should be put on a robust basis right from

the start. In other words, potential interference factorsthat might obstruct the process should be identified and

taken into account at an early stage. Obstructions may be

internal, for example, departments working against each

other, or there may be technical problems. Those who

detect issues early and find solutions have good pros-

pects for overcoming the hurdles and for growing with

innovations.

Dr Mller-Prothmann, many thanks for this interview.

VI

VII

V

IV

III

II

I

compeence 02.2011 /


12/80

ThinkTank KHS page 1245

Companies ha wan o play a op level in he Champions League o

heir indusry and repeaedly be in charge o heir own desiny mus subjec

hemselves and heir producs o a coninuous improvemen process. /

In line wih his moto, he KHS eam did no resign o sagnaion in imes

ha were difficul or almos all companies, bu insead pushed orward inno-

vaion in producs, processes and echnologies wih even more inensiy

and dedicaion. This is in he ineres o he cusomer who hus receives sus-

ainable produciviy advanages and, as a resul, also gains cos and

compeiive advanages.

INNOVATIONSha give our cusomers more

Innovaion


13/80

14 New generation of fillers

22 New standards in aseptic linear PET fillers

28 New resource-saving CIP cleaning system30 New keg line for medium-sized businesses

34 New packaging system for shrink packs in the retail sector

38 New space-saving labeling machine

40 New deluxe shrink packer

In the Innovation box, you will find a QR code (left) pertaining to each article. Use your

smartphone to create a direct email contact to the corresponding contact person.

For this, simply download a corresponding application (app) and scan in the code withthe smartphones camera. You can do this with the following free apps, for example:

iPhone AppStore RedLaser

Android Market Barcode Scanner

Blackberry App World BeeTagg

compeence 02.2011 /


14/80

KHS presens he innovaive filler

plaorm or glass botles /No only

he echnology o he new, innovaiveglass botle filler concep Innofill

Glass by KHS is he Bes o he Bes.

Whas more imporan is ha he

opimized Hygienic Design concep

will give he companies who use i

direc compeiive advanages. These

include improved filling qualiy and

considerable cos reducions. For

echnicians and businessmen alike,his is he suff o dreams.

NEW

ERA

Innovaion


15/80

A a glance:Innofill Glass

Increased filling quality

Faster cleaning

Higher availability

Reduced maintenance costs

Lower energy costs Less water consumption

Less cleaning media

Short changeover

are achieved through comprehensive

hygienic design and modern, lubrication-free

components with optimized wear

properties developed by KHS with its highly

specialized partners.

compeence 02.2011 /


16/80

Until now, beverage machine engineering normally opti-

mized many individual components in terms of hygienic

design without considering the adjacent machine parts.

Problems: Optimizing, modernizing, and changing over

existing designs always reach limits and obstacles as

long as the basic design needs to be preserved. Hygienic

design thus remained piecemeal. Solution: the complete

redesign of a filler line in that all design steps focus on

the hygienic design aspect from the beginning without

any regard of currently existing components. The team

put everything to the test, reassessed every detail andeventually implemented the knowledge gained in inno-

vative systems.

The result is a platform-based machine concept as we

find in the automotive industry. There, a platform defines

the common technical basic concept, and the functions

of the different models are oriented towards that basic

concept. The definition at KHS is similar. A technical basis

is now available that the different computer-controlled

KHS filling systems are built on and that takes the respec-

tive individual criteria of the specific filling methods into

account. The first filler for the KHS Innofill Glass platform

system is the DRS-ZMS pressure filling system used forbottling beer. Other filling systems for soft drinks, water,

wine, sparkling wine, and spirits will follow.

KHS thus heralds a generation change in filling ma-

chines for glass bottles that offers a wide range of ben-

efits, such as an even better filling quality, higher line

availability, and reduced cost of maintenance, power,

water, and cleaning agents. This is achieved primarily

thanks to the use of modern and lubricant-free com-

ponents with optimized wear behavior, which KHS has

developed in close cooperation with its highly special-

ized partners.

French writer, painter and graphic artist Francis Picabia

(1879 to 1953) discovered, our head is round so our

thinking can change direction. The master was look-

ing far ahead into the twenty-first century. Because, as

Michael Batz, dramatic adviser and light artist from

Hamburg (Reichstag, Speicherstadt Hamburg), put it,

for some time already, it is not either/or exclusivities,

individual highlights or more or less rigid systems what

matter. Thinking today is formed by plurality, controlla-

bility that should be as easy as possible, time manage-

ment and the ability to communicate combined withlow energy consumption and high efficiency.

In addition, and as the basis of all considerations, KHS fo-

cuses constantly on the customer in its market. What are

the latters requirements? What does the customer needfrom a technological and economic perspective? How

does the customer gain a lasting competitive advantage

through KHS technology and services? These were exact-

ly the questions the developers in the KHS group asked

themselves when they worked on an innovative system

for glass filling lines, which is now ready for operation.

The focus here: hygienic design and automation. Compet-

itive companies regard hygienic design as a major criteri-

on for lowering costs in production. Above all, however,

it is about secured product quality and protection of the

consumer, but also about health at work for the own staff.

Is abou secured produc

qualiy and proecion of he

consumer

Our head ,

Innofill Glass: Significant reduction in weightand parts in the filler carousel.

Innovaion


17/80

THE NEW TECHNOLOGY AT A GLANCE

Hygienic design is always also a mater o calculaed simpliciy.Simple design rules are hereore indispensable:

Easy access to all machine surfaces (sanitizing, disinfection, inspection,

maintenance).

Avoidance of complex machine surfaces (wherever possible).

Avoiding hidden areas (where deposits and biofilms can accumulate).

Unobstructed runoff of liquids.

Basic design.The function of the basic design in brief is to feed glass bottles into the machine, supply them

to the filling and capping process, and subsequently dis-

charge filled and capped bottles from the machine. The fo-

cus of the development work was therefore to design all

parts relating to bottle conveying, with focus on hygienic

design. Key features: supporting pipe bodies that are open

on all sides (optimally accessible for cleaning and disinfec-

tion) / broken glass falls directly to the floor and is easy to

remove / stars and cappers are interconnected by flange-

less cross-pipes and secured towards the outside by hygien-

ically designed sealing systems / all bottle format parts are

compeence 02.2011 /


18/80

Torque motors.Transfer stars and cappers operate with

low-wear and energy-efficient torque motors (without

gearbox) / high torques / no mechanical abrasion / 96%

efficiency [conventionally: 85%] / minimized wear / long

service life). The energy conservation potential is up to

20%. Another advantage is the hollow shaft design. Me-

dia are fed through the hollow shaft for injection at high

pressure, for example.

Filling system. The Innofill DRS-ZMS filling process has

been optimized further. At the same time, however, thetried-and-tested filling process principle is essentially main-

tained (filling level probe / triple evacuation / double CO

rinsing / fast filling phase / precise fill level measurement /

low-foam pressure-controlled pressure relief / speed-in-

dependent filling process / option for central changing of

valves at any time).

Modifications:Optimized swirler allows for improved

low-turbulence and smooth filling while ensuring minimum

oxygen pick-up / bell rods exposed to the outside and sloped

surfaces ensure easy cleaning of the filling valves / hose con-

nections no longer need to be hooked up separately.

Electrical elements.There are no electrical elements, cables,

or pneumatic supply hoses in the area of the filling valves

and bottles / controlling pilot valves are arranged within a

protected area, completely encapsulated in a housing.

Compact valve manifolds. Fittings are specifically con-

structed vertically and not horizontally / this offers the ad-

vantage of taking up 50% less space; maintenance and

checks are easier / compact valve manifolds are positioned

in the immediate vicinity of the filler cladding / advantages:

media passages are very short; quick, and efficient cleaning.

designed to allow for optimal cleaning / weight-reduced

design with easy-to-operate shape and position fixing

locking pins / container format parts can be changed eas-

ily and quickly without any tools.

Conveyor. A new stainless steel conveyor with open de-

sign conveys the glass bottles directly to the feed screw.

An automatic cleaning system can be integrated. The

feed screw has no large surface areas. Instead: many

rounded and sloped surfaces allow liquids to run off / the

unit is driven by a stainless-steel encapsulated round ser-vomotor / attachment systems comprising bottle glide

and guide strips (automatic cleaning) prevent the forma-

tion of gaps and niches where beverage residue could

accumulate and microorganisms could grow.

Machine carousel. The lightweight construction of the

lift cylinder table and the tubular ring bowl additionally

reduces the required driving forces / the tubular shape

of the ring bowl allows for efficient cleaning results /

the significantly reduced amount of materials saves en-

ergy by shortening the heating and cooling phases /

electrical signal and output transmission to the carouselby maintenance-free rotary distributors / linear drive

technology adjusts the height of all outer control cams

and stop segments (control ring with additional height

adjustment motor, angle gears, universal joint shafts

and lifting columns are no longer required) / bottle-

lifting elements offer more room for discharging bro-

ken glass / height-adjustable scissor joints equipped

with aseptic sealing systems supply beverage and pro-

cess media. The result is a noticeably reduced number

and variety of parts in the filler carousel (more efficient

cleaning and maintenance).

1

Ludwig Clsserath, Manager, Filling TechnologyCompetence Center: KHS is introducing a new era infilling technology with the Innofill Glass concept.

Injection of water at high pressure into filled beerbottles: the medium is fed through a hollow shaftwithin the torque motor.

2

1

Innovaion


19/80

2

compeence 02.2011 /


20/80

of these pumps differed as far as their electrical systems or size and

equipment are concerned. In the future, KHS will offer a standardized

vacuum pump model. Only the following decision must be made de-

pending on the output of the filling system: does the filler require one,

two, or three identical vacuum pumps?

When bottling beer in glass bottles, vacuum pumps reduce oxygen

pickup and CO consumption thanks to gas exchange. The standard

practice to date has been to customize only one vacuum pump for the

respective filling system, for example in terms of the filling output, the

product temperature, or the CO content in the product. Many versions

Vacuum Pumps: Sysemaic ModulesAs par o he new produc line or glass botles, KHS presens a sandard model or vacuum pumps ha is also modularin design. Naurally, i also offers a large number o advanages or botling plans. And, whas more, i already ulfilsEU regulaions on energy efficiency, which will become effecive in 2017.

Example: becoming flexible!An example o minimized power consumpion and parial redundancy/redundancy:a filling sysem processes 50,000 0.33-lier or 50,000 0.5-lier glass botles.

Capacity in the operating point:

14.5 kW at 50 Hertz

Possible output of vacuum pump:

26,000 liters per hour

Possible line output if one

pump fails:

The line stops

IN THE FUTURE: TWO VACUUM PUMPSWITH A CONNECTED LOAD OF 15 KW EACH.

Number of active pumps: 1


50 to 60 Hertz / 8 to 12 kW

Possible output of vacuum pump:

16,500 liters per hour


pump fails:

100%

(50,000 bottles/hr x 0.33-liter bottles)

If one pump fails:

Second pump is switched on

Number of active pumps: 2


50 to 60 Hertz / 12 to 16 kW

Possible output of vacuum pumps:

25,000 liters/hr (2nd pump switches in*)


pump fails:

75%

(37,500 bottles/hr x 0.5 liters/bottle)

If pump fails:

Second pump capacity is regulated upward

Opion 2: 0.50-lier glass botlesOpion 1: 0.33-lier glass botlesBoh versions

UP TO NOW: ONE VACUUM PUMPWITH 18.5 KW CONNECTED LOAD.

*At a low frequency value always in optimal operating point

Contact: Olaf Muszinski | KHS GmbH, Bad Kreuznach, Germany | Phone: +49 (671) 852 -2704 | Email: ola.muszi [email protected]

Innovaion


21/80

Vacuum pump. For the new product line, a single pump

type is sufficient; depending on the output, up to three

are connected in parallel. This saves costs and reduces the

footprint, lowers power and water consumption and en-

sures fast supply with spare parts.

Crown capper.A more open design improves cleaning of

many individual elements / closed servo motors substi-

tute belt drives and other driving systems that were oper-

ated by belts or gear wheels / most important innovation:cappers for other closure types can be added like mod-

ules without any preparing investment and can easily be

docked to the platform (open bottles do not need to pass

through existing capping systems).

Exterior cladding.Free-standing, makrolon or glass exte-

rior cladding / advantage: unobstructed view of all ma-

chine components / dirt and deposits can be seen immedi-

ately from the outside / sufficient access area for cleaning

and maintenance / basic exterior cladding can be upgrad-

ed to a closed sanitary room.

Timesaving. Rapid intermediate rinsing and cleaning

processes during product change / lines are installed

with a slope to ensure quick emptying of the product pas-

sages / advantage: significant time savings for frequent

changeover / in addition, reduced time for machine in-

stallation and initial operation.

Diagnostic system. Optionally, reference filling valves

can be equipped with pressure sensors that continuous-

ly record the pressure curve during a filling process and

send it to the display screen. This has the advantage that

the process sequence can be monitored permanently

even inside the bottle. The vacuum actually achieved in

the bottles and the correct CO purging process can be

read, among other things.

This is an important aspect in order to ensure low-

oxygen filling.

Operator panel. The new multiple-award winning KHS

operator panel (Red Dot Award & iF Award) with integrat-

ed RFID system controls the platform system.

Conclusion:Innofill Glass rings in a new area in filling tech-

nology. The platform offers maximum transparency and

cleanliness while ensuring even greater product safety.

Oriented towards the requirements of the brewing trade

to be able to fill beer pasteurized by a flash pasteurizer

under optimal hygienic conditions without the need for

bottle pasteurization after the filling and capping pro-

cess, KHS development experts have done a perfect job.

Light artist Michael Batz sees it this way: It is neither the

wind nor the sun thinking is the largest renewable en-

ergy source.

Contact

Ludwig Clsserath

KHS GmbH,

Bad Kreuznach, Germany

Michael Beisel

KHS GmbH,


Phone: +49 (671) 852 -2501

Email: ludwig.cluesse [email protected]

Phone: +49 (671) 852 -2205

Email: michael.be [email protected]

3 4

Just one type of vacuumpump is sufficient forthe new range. Up tothree can be connectedin parallel dependingon the capacity.

The KHS operatingpanel has received manyawards thanks to out-standing ergonomics,accurate navigation andbrilliant design.

3

4

compeence 02.2011 /


22/80

New generaion o asepic linear fillers rom KHS

/

Now, asepic cold filling o PET botles or

non-carbonaed beverages or oher liquid producs isbecoming more flexible, easier, and more cos-

efficien. Wih Innosep Asbofill ABF, KHS ses worldwide

sandards, or example wih minimum serile zones

or numerous opions and one drop o liquid nirogen.

Maximum

Sandards

Innovaion


23/80

New generation of linear filling machines:Innosept Asbofill ABF 611 and Innosept Asbofill ABF 711process up to 12,000 PET bottles per hour ranging between100 ml and 2.0 liters. A twin concept doubles the capacity.

compeence 02.2011 /


24/80

Whats new is that KHS has developed a young generation

of aseptic linear fillers which incorporate many optimized

features. Users thus have a whole package of benefits if they

choose the process of so-called dry bottle sterilization be-

fore the filling process. This principle also applies to the new

aseptic linear fillers Innosept Asbofill ABF 611 and Innosept

Asbofill ABF 711 from KHS that reduce the required sterile

area significantly compared to the classical ACF wet pro-

cess. Instead of the 65 cubic meters necessary, only 15 cu-

bic meters are required when using the rotary design prin-ciple, while in linear operation the sterile area is drastically

reduced even further which is the decisive benefit that

linear technology offers. The Innosept Asbofill ABF 711, for

example, requires a sterile area of just 1.5 cubic meters and

the Innosept Asbofill ABF 611 only 0.9 cubic meters.

At the same time, this reduced area offers maximum asep-

tic safety as the system conveys the bottles in a single hold-

er through the entire machine. No switching from one car-

ousel to the other as is the case in the rotary system is

required. Thus, mechanical intervention in the aseptic

zone is not necessary. All conceivable conversion and re-

placement measures take place in the unsterile area. An-

other benefit of the linear machine compared to the rota-

ry system is that intermediate sterilization is not required.

Oriented fully towards the respective product to be filled,

the production cycle is between 48 and 72 hours.Aseptic linear filling machines generally cover a low

to medium output range. The new lines process up to

12,000 plastic bottles per hour (24,000 with the twin con-

cept) with different shapes. Special sizes, including rectan-

gular or square, are possible. The ABF linear fillers have

been designed for filling non-carbonated beverages, such

as milk, yoghourt drinks, fruit juices, and fruit juice drinks.

Pulpy beverages containing up to 20% pulp and with

fiber lengths of up to 18 millimeters can be processed. In

addition, Innosept Asbofill ABF 611 and Innosept Asbofill

ABF 711 are optimally suitable for filling pharmaceuticals,

The basic three advantages of aseptic cold filling inplastic bottles are known. Firstly, natural taste andaroma of the beverages as well as their color are pre-

served. Secondly, the lighter, cost-efficient cold-fill PET

bottle can be used instead of the thick-walled hot-fill bot-

tle. Thirdly, preservatives are no longer necessary.

Our cusomers produce more

effecively and more cos-efficienly.

Tha was wha matered o us.

Paul-Uwe Winterhoff

Head of Mechanical and Electrical Design,Competence Center Aseptic Filling Technology

In linear operaion,

no mechanical inervenion is

required in he asepic zone.

Innovaion


25/80

+ Measuring instruments. All measuring instruments are

new-generation components. Advantages include improved

ease of operation and optimized information density.

+ Machine capacity.A twin-concept doubles the original

machine capacity. This has the advantage of long-term

reduction of cost compared to the investment in two in-

dividual machines. The reason for this is that essential

components can be shared. Only one valve manifold, one

bottle conveyor, one product and steam supply, one con-troller, one operator terminal and one machine cladding

are required, for example. Added to this are the cost ad-

vantages of reducing spare part stock keeping. In addition

to requiring less space.

The mos imporn saions in brie

An air conveyor carries the PET bottles reliably and gently

by means of neck handling while maintaining best pos-

sible hygienic conditions. Each section has a frequency-

controlled blower that supplies the air channel and con-

trols the conveying speed of the bottles by means of

various volume flows.

Infeed of the bottle is outside the aseptic zone. A chain

moves past the air conveyor. The end of the latter is pro-

vided with a curve that ensures that the bottles are insert-

ed in holders specially integrated into the chain for thispurpose (the Innosept Asbofill ABF 611 has 24 holders, the

Innosept Asbofill ABF 711 has 30 holders).

After the checking process, the bottles are transferred

to the sterilization zone where the system introduces

HO aerosol with temperatures between 90 and 120 C

into every bottle in cycles by means of a lance positioned

directly underneath the neck. All surfaces are uniformly

coated regardless of the size and shape of the bottle.

A partition separates the sterilization and the filling

process in different housings. The aseptic zone always ex-

tends from the bottle mouth to the neck ring. Accordingly,

provided they are liquid products for enteral feeding or

health drinks for example.

Possible, rerofitable opions

Users can also integrate all options for the individual en-

trepreneurial practice later.

+ Pulp nozzles.Pulp nozzles can be installed in the filling

valves, especially when fruit juices with high pulp content

are to be processed.

+ Nitrogen.Especially for beverages sensitive to oxygen:

nitrogen flushing before the filling process and flushing

of the head space of the plastic bottles with nitrogen af-

ter the filling process. This has the advantage that oxygen

in the beverage is reduced even further.

+ Liquid nitrogen. Another possible option is to place a

drop of liquid nitrogen in the head space of the filled plas-

tic bottles. The advantage of this process, which has been

uniquely designed for linear fillers, is that more oxygen is

displaced. It is especially suitable for lightweight bottles.Also: the pressure inside the PET bottles ensures greater

bottle stability. This results in improved subsequent process-

ing such as labeling, palletizing, and conveying. And final-

ly, the fact that less plastic is used saves material and costs.

+ Filters.Double filters can also be used in the valve mani-

fold instead of single-filter units.

+ Code.Further options include coding of the plastic bot-

tles during the production process.

Much easier a several levels

+ Sterilization zone.The number of components in the

sterilization zone has been reduced even further. For ex-

ample, only one single servomotor is used for all drying

lances. Advantages include easier maintenance and low-

er operating cost.

+ Cable routing. The cable routing has been optimized

even further, the location of the HO treatment and oth-

er units has been changed. This has the advantage of even

better machine accessibility.

Permanen serile air

in he

asepic zone.

compeence 02.2011 /


26/80

A a glance:he new asepic linear fillers

Criteria Innosept Asbofill ABF 611 Innosept Asbofill ABF 711

Process Aseptic cold filling in PET / dry sterilization

Suitable for Non-carbonated beverages, liquid products, e.g. pharmaceutical

Sterile area 0.9 cubic meters 1.5 cubic meters

Capacity 12,000 PET bottles per hour twin concept: 24,000

Standard bottles 0.1 to 0.75 liters 0.25 to 2.0 liters

Standard diameter Bottles up to 85 mm Bottles up to 120 mm

Standard height Bottles up to 240 mm Bottles up to 350 mm

Neck ring Constant 38 or 43 mm

Options

Pulp nozzles for products containing fruit / nitrogen flushing before

and after the filling process for products sensitive to oxygen / liquid

nitrogen for displacing oxygen / double filters in the valve manifold /

coding during the production process

Special advantagesEasier to operate (improved accessibility) / cost-reducing options

(lighter bottles, time saving, higher availability)

Innovaion


27/80

a partition also extends only up to the cell carrier bar and

only contains openings for the necks of the individual

plastic bottles. Sterile air is blown permanently into the

area of the aseptic zone and is discharged downward by

so-called positive displacement current via an adjacent

perforated plate.

From there, it enters the machine room where it can ei-

ther escape or be specifically extracted. The actual sterile

air preparation is located in a valve manifold installed on

the machine, which also provides other media required for

the production process. Blowers convey the air to the valve

manifold that includes candle sterile filters. Candle filters

offer the advantage that they can be sterilized with steam

prior to production. Any microorganisms that might be

present are thus reliably destroyed while ensuring maxi-mum process reliability.

Filling is carried out in two stages using the safe, asep-

tic open jet process with a filling valve which has been spe-

cially developed for low-foam filling. The preset filling rec-

ipes can be accessed by pressing a button on the operator

terminal. Filling by means of electromagnetic inductive

flowmetering allows for exact fill levels without any over-

fill (product savings). Changeover to other bottle sizes is

completed at the push of a button.

An adapter located within the filling station closes

the filling valves for cleaning. The result: continuous circu-

lation during the cleaning process of the filling valves. Theentire aseptic zone is always cleaned by foam cleaning pri-

or to production. In this process, every individual place in-

side the aseptic room is reliably reached.

Possible closure types include seals (for dairies for ex-

ample) or screw caps (for example for fruit juices). The cap-

ping process always takes place in a housing that is sep-

arate from the filling process. Consequently, the bottles

pass through a partition again after filling.

From the beginning, the sealing process is fully auto-

matic. It is no longer necessary to place seals in hoppers

provided for this purpose. This has the advantage that

aseptic safety is increased even further while operator er-

rors that might result in malfunctions are prevented.

From the sorter, plastic closures are transferred into a

feed chute. Aligned in the same manner, the caps fully

oriented towards the number of plastic bottles conveyed

at each cell carrier bar are distributed on eight lanes in the

Innosept Asbofill ABF 611, and respectively on ten lanes in

the Innosept Asbofill ABF 711. Sterilization is the same as

bottle sterilization. Application of the screw caps has been

thought out right down to the last detail. In a first step, asuction unit places the caps on the bottles, which are thus

largely protected against external influences. The capper

housing is divided into two chambers; the aseptic zones of

these are separated by partitions. In the next step, the caps

are screwed on in a separate sterile chamber. The key ad-

vantage is that the rotary capping motion, which usually

entails greater risk in the aseptic zone, takes place within

a sterile zone in which the bottles are as good as sealed.

Maximum aseptic safety is also the motto here. Apart from

classical plastic screw caps, sports caps can optionally also

be processed (retrofittable).

This step is followed by the closure check. After that,the bottles are clocked up to a position from where a

gripping system takes them out and places them on the

conveyor.

Conclusion: With the new generation of aseptic lin-

ear fillers, KHS offers a technical system that fulfils the

demands required by companies. Maximum safety goes

hand in hand with flexibility with regard to the product

and also the plastic bottles to be filled and the closures

used on them. Thanks to a comprehensive package of op-

tions, which can also be integrated into the latest genera-

tion of Innosept Asbofill ABF machines later, this is a ma-

chine generation that is perfectly equipped for the presentand the future.

Phone: +49 (671) 852-2900

Email: homas.niehr@k hs.com

Phone: Phone: +49 (671) 852 -2900

Email: paul-uwe.wine [email protected]

Contact

Thomas Niehr

KHS GmbH,


Paul-Uwe Winterhoff

KHS GmbH,


As here is no overfill,

produc is saved.

compeence 02.2011 /


28/80

SHORTROUTES

Quesion 1: Wha are he benefis?The Innopro CIP C is a local CIP system that not only cleans

the filling system but also an additional process compo-

nent, such as the flash pasteurizer or the mixer, as well

as itself. The key advantage of this solution is that me-

dia transport over long distances is avoided. Compared

with conventional CIP systems the energy consumption is

therefore significantly lower, because thanks to the cen-

tral position and short media lines the heating losses are

much reduced. In addition, media consumption is lower,

and the smaller number of mixing phases means that the

cleaner uses much less water and cleaning media.

In the beverage sector it goes without saying that fill-ing lines have to be perfectly clean. This is what CIP(Cleaning in Place) is for. This process reliably removes pro-

duction residues, deposits, and product-harming micro-

organisms. The new Innopro CIP C (Cleaning in Place Com-

pact) system developed by KHS offers even more. It saves

water, chemicals, energy (and therefore costs), doesnt re-

quire a lot of space, and can easily be integrated in new

or ex isting filling lines. From a filling operation perspec-

tive there are ten important questions regarding the ap-

plication in practice.

New, resource-saving cleaning sysem rom KHS/

The newly developed Innopro CIP C cleaning sysem

offers noiceable addiional resource savings and

an invesmen plus o around 15%. A clever aspec is

ha long roues or media ranspor are avoided.

Innovaion


29/80

Quesion 2: For which applicaions

is he cleaner suiable?

The Innopro CIP C can be used for a wide range of filling

applications, such as beer, water, soft drinks, juice, wine,

or milk, and containers such as cans, glass, plastic bottles,

or kegs. It is equally suitable for cold filling, aseptic filling,

ultra-clean filling, and hot filling.

Quesion 3: Wha is he echnical concep?

The Innopro CIP C is equipped with three tanks: a caus-

tic tank, a hot water tank, and a primary water feed tank

which serves as system isolator. This has the advantagethat the CIP flow pump cannot run dry and always has

water available, even in the event of an overload of the

water network.

Quesion 4: How long does he insallaion ake?The tanks of the Innopro CIP C have been deliberately de-

signed as rectangles. This makes the whole system compact

and suitable for standardized overseas containers, result-

ing in cost-effective transport. All components required for

the system operation such as pumps, valves, heaters, media

tanks, and the control cabinet with the controller are already

installed on a stainless steel frame in the container and ready

for operation.

Quesion 5: How does he Innopro CIP C work?

The cleaning media and the hot water are heated using

a plate heat exchanger and saturated steam. The clean-ing temperature is controlled electropneumatically. A

flow pump ensures circulation of individual cleaning me-

dia and maintains the cleaning pressure. While the fresh

water is immediately disposed of after the first cleaning

process, the conductivity and temperature of the caustic

are measured after the cleaning process. Should returned

caustic be discarded or returned to the caustic tank and

therefore the production process? The pneumatic meter-

ing system adds caustic. The system is then rinsed with hot

water and finally with cold water in order to cool down

the piping and components.

Contact

Alfons Abels-Rmping

KHS GmbH,

Bad Kreuznach,

Germany

Phone: +49 (671) 852 -2211

Email: alons.abels-rue [email protected]

Quesion 6: Can acid be used or cleaning?

Deposits are removed with acid. With the Innopro CIP C,

acid can be introduced into the existing hot water tank

and from there fed to all components.

Quesion 7: How does he sysem clean isel?

The Innopro CIP C automatically deals with regular self-

cleaning. The CIP media is introduced into the respective

tank using spray balls. At the same time the spray balls

flush the tank walls with cleaning solution or rinsing wa-

ter, resulting in optimum cleaning.

Quesion 8: Manual or auomaic?

The system offers a choice between manual and fully au-

tomated operation. In manual mode the operator has to

switch on the flow pump or the steam and fresh water

supply, for example. In fully automated mode all process

steps run as stored in the recipe.

Quesion 9: Wha accessories are available?

The options are limited in order to keep the system clear

and simple. Possibilities: Reasonably priced insulated

media tanks (for additional energy savings) are available

as an option, as are tanks in standard stainless steel.

Quesion 10: Are special service opions available?

Included as standard: ReDiS (Remote Diagnostic Service)

is included as a standard. If assistance is required, you can

contact the KHS ReDiS Service Center directly. The possi-

bility of reprogramming through ReDiS increases the sys-

tem availability.

Conclusion: The Innopro CIP C not only offers numerous

technical and system benefits, but also an investment ad-

vantage of around 15% compared with standard CIP sys-

tems. This is achieved by deliberately using a compacttank unit. The standardized system design minimizes the

design effort.

Innopro CIP C:

a rue ecological package.

compeence 02.2011 /


30/80

A RealAll-Rounder

Innovaion


31/80

empty kegs onto the infeed conveyor and, without having

to walk any distance at all, subsequently remove and pal-

letize the racked kegs straight off the discharge conveyor.

Another exceptional feature is that the system is modular,

enabling a great number of options.

The basic Innokeg Till CombiKeg R 3 machine has three

washing heads and one racking head, and works with

a classic, pressure-dependent racking system and re-

turn gas control. Performance: 60 kegs per hour. The

Innokeg Till CombiKeg R 5 is fitted with five washing

heads and one racking head, and uses the patented KHS

Direct Flow Control (DFC) filling process (which can also

be integrated into the basic machine at any time). Per-

formance: up to 90 kegs per hour. Further peripheralcomponents, such as scales, keg turners, keg cappers,

and cameras can of course also be integrated into the

system concept.

The cladding, which is fixed within the machine frame

and is designed in accordance with Hygienic Design spec-

ifications, is easy to clean and enables optimum process

control and rapid maintenance access. Tried-and-tested

KHS washing and racking heads, simple, clearly arranged

matrix piping, and the use of hygienic membrane valves

for media supply make for easier servicing and reliable

processing.

KHS has developed a special keg line or medium-sized businesses/

Special characerisics: very low space requiremen, low budge, sysem

efficiency o 95%, capaciy o up o 90 kegs per hour, expansion opions.

The pilo sysem is running successully.

Ahot tip for companies in the brewing, soft drinks, min-eral water, fruit juice, and wine segments whose kegfilling capacity is unlikely to exceed 90 kegs per hour in the

future is the Innokeg Till CombiKeg. The new development

from the market leader in keg technology is an extremely

compact keg washing and racking machine.

All processes are integrated within a single frame and

include external and internal cleaning, the filling process,

up to five media tanks, the control system, and an infeed

and discharge conveyor. The system fits exactly into onecontainer and is ready-piped, cabled, and thoroughly pre-

tested in the KHS plant. It can therefore be installed, con-

nected up, and commissioned at the filling plant in just a

few days. Once the media and product connections have

been prepared on site, all that remains to be done is to

erect and connect up the machine, press the start button,

carry out the first CIP operation and production can start.

Long live the Plug & Produce principle!

Feaures and advanages

The new Innokeg Till CombiKeg processes 60 to 90 kegs

an hour and is based on the principle of rotary process-ing which has been successfully employed and continu-

ously developed by KHS for several decades. Advantages

include cyclic processing and a low space requirement.

If more than 90 kegs per hour are to be processed on a

continuous basis, KHS recommends the in-line Innokeg

Till Transomat which can be expanded without difficulty.

But back to the main features and advantages of its

little sister, the Innokeg Till CombiKeg. With this machine,

the infeed and discharge areas are not separate but are

arranged directly next to one another, making them ex-

tremely user-friendly. Just one operator can place the

Three or five

washing heads, depending

on capaciy.

Insights: Infeed station and first cleaning head; the exteriorcleaning booth is on the right in the background.

compeence 02.2011 /


32/80

Filling takes place after the keg has been rinsed with

hot water and finally blown out with steam. The filling

process uses either the classical, pressure-regulated fill-ing system or the DCF filling process with its advantag-

es of a 40%-lower CO consumption, extremely accurate

filling control, and reduced oxygen pickup for improve-

ment of the product quality. The whole process is distin-

guished by significant savings in water, waste water, and

energy. An important aspect is that, for uncomplicated

products, fewer steps and a less complex machine design

are possible.

Once the keg has run through the racking process,

it is sent on to the discharge station. Here, a check shoe

pushes it from the machine onto the discharge conveyor.

Proven echnology

If the kegs are severely contaminated, the keg fittings can

be sprayed with water as they travel along the infeed con-veyor. This ensures that no particles of dirt which may be on

the fitting are washed into the inside of the keg. Essential

features of the cleaning process naturally include a leakage

test, the blowing out of any remaining beverage with ster-

ile air, and optimum pulsating cleaning with up to three

cleaning media. As an option, the exterior keg washer can

be incorporated into the system housing. The space within

the system intended for the exterior washer otherwise re-

mains unused. The system achieves optimum soaking of the

interior of the keg with caustic using two stations. Retro-

fitting is possible without any problems.

Innokeg Till Combikeg compact keg washer andfiller. Specially for small and medium-sized companiesin the beverage industry.

Innovaion


33/80

An operator removes the keg or, in the case of bad kegs, a

warning signal is given. An automatic rejection station for

bad kegs can be provided. An automatic palletizing sys-tem is also conceivable.

The Innokeg Till CombiKeg also processes non-re-

turnable kegs. To this end KHS also supplies the Petain-

er keg, developed in cooperation with Petainer UK Hold-

ings Limited. All thats needed to rack them are additional

adapters made of plastic. These are pushed onto the plas-

tic kegs prior to treatment so that they form a single unit

during the washing and racking process.

Conclusion: The Innokeg Till CombiKeg is in every

respect an advantageous all-rounder for medium-sized

businesses. The system not only cuts down on costs and

required space but also provides tried-and-tested washing

and racking quality with maximum flexibility and a line ef-

ficiency of 95%. This is not only of interest to the Europeanmarket but also to already growing keg markets, such as

that in the USA (in particular amongst craft brewers), and

the still developing keg markets in Asia and Africa. And if

that isnt a hot tip

Werner Dinkelaker:As we know that we

can rely on KHS in every respect, we were con-

fident in investing in the pilot system for the

newly developed Innokeg Till CombiKeg. In

retrospect, this was exactly the right decision.

Gustavo Tresselt:Because our proportion of

kegs is high, it was important for us to invest

in a robust, reliable system which takes into

account our high quality requirements.

Werner Dinkelaker:And it also saves space.Our operators dont feel constricted in their

work, even in this small space. It wouldnt

have been possible to install a conventional

inline machine.

Gustavo Tresselt:There are no long dis-

tances with this system, as is common with

inline machines. This saves us an operator.

Werner Dinkelaker:Sustainability as a com-

pany tradition starts with the little things. We

are very careful to use resources sparingly in

every respect.

Gustavo Tresselt:Actually, we hadnt in-

tended to include the brushing station in our

machine. Then during the KHS in-house exhi-bition we noticed that kegs which had been

brush-cleaned looked considerably better. An

advantage with this option is also that the

brush is automatically perfectly matched to

the particular keg diameter to be processed

by means of an electric adjustment motor.

Gustavo Tresselt:We are extremely sat-

isfied with our Innokeg Till CombiKeg. Our

confidence in KHS and our courage to invest

in the pilot system have been rewarded by us

gaining a reliable, compact system.

Werner Dinkelaker:This will enable us to

approach the future positively. However, we

are also planning growth in the future, notfor growths sake but only if the profits are

right. And also because our beer means a lot

to us. At Schnbuch, we believe in beer qual-

ity in the truest sense of the word.

Contact

Rainer Deutschmann

KHS GmbH, Kriftel,

Germany

Phone: +49 (6192) 491-130

Email: raine [email protected]

The Schnbuch Braumanuakur in Bblingen near Sutgar is now in is sixh generaion and managedby Werner Dinkelaker and Gz Habisreiinger, ably suppored by maser brewer Gusavo Tressel.Their company is already using he Innokeg Till CombiKeg pilo sysem rom KHS. In he ollowing, woexpers o he rade voice heir impressions o and describe heir firs-hand experience wih he new sysem.

Pracical experience speaks or iselInnokeg Till CombiKeg pilo sysem a Schnbuch Braumanuakur

compeence 02.2011 /


34/80

TEMPOTEMPO

T E M P O

Innovaion


35/80

One o he larges mineral waer botlers in

Germany now uses KHS echnology or preparing

and palleizing shrink packs/ Wih he Innopal PBL,

Mineralquellen Bad Liebenwerda is able o dis-

ribue a wide range producs in differen sizes o

pack, loaded ono a single palle rom our se-

parae conveyor secions.

VEB operation. Since then the company has been on the

up continually. By the end of 1991 the number of fill-

ings was already 14 million, in 1992 it was 50 million,

by the turn of the millennium 110 million, and in 2010

150 million.

The KHS assembly line for shrink packs can process up

to 18,000 non-returnable PET bottles per hour. The line cur-

rently manages six-packs with 1.5 and 0.50 liter bottles. It

is planned and this will also be possible in the future for the line to handle 0.75, 0.33 and 0.25 liter bottles. Op-

erating personnel used to stack the shrink-wrapped packs

manually. Now four conveyor sections can optionally han-

dle different products. Costly and comparatively slow man-

ual assembly will therefore be a thing of the past.

Pracical example

Conveyor section 1: Shrink packs with mineral water.

Conveyor section 2: Teetrume shrink packs.

Conveyor section 3: Soda pop shrink packs.

Conveyor section 4: Landtrume shrink packs.

Retailers are in a quandary: On the one hand they wantto offer a comprehensive product range, on the oth-er hand they have only limited storage space. This also ap-

plies to the suppliers. Horst Kuhl, managing partner of

Mineralquellen Bad Liebenwerda in Brandenburg, reckons

that this is also relevant for suppliers: Brand suppliers have

to be proactive and quick. This is precisely why his compa-

ny recently invested in a KHS line with the sole task of au-

tomatic assembly and palletizing of a wide range of shrinkpacks for different non-returnable PET bottles. The advan-

tage for retailers is that they receive all the shrink packs

they ordered ready mixed on a pallet, which saves space.

With the new KHS line, Mineralquellen Bad Lieben-

werda present themselves as industry innovators, and

not for the first time (see company telegram on page

37). The company is one of the first mineral water op-

erations worldwide to use this trend-setting concept.

Tempo has always been a trademark of Mineralquellen

Bad Liebenwerda. Shortly after the German reunification

the RhnSprudel group took over the former powerful

Inline robot grouping enables side-clamped shrink packsto be gripped, turned and moved with millimeter accuracyand with considerable space saving.1

compeence 02.2011 /


36/80

Contact

Jrg Hoffmann

KHS GmbH, Dortmund,

Germany

Phone: +49 (231) 56 9 -1877

Email: joe [email protected]

centering device arranged beneath the pusher plate. Also

integrated is a handling robot that uses suction elements

to remove pallet liners from a magazine and position

them on the current layer.

The individual layers are palletized on half pallets or

Euro pallets. Additional gripper elements arranged on the

suction head of the handling robot position the pallets in

the predefined position. A stretch film wrapping machine

secures the load. This is followed by pallet labeling, trans-

fer to a forklift truck, and transport to the store.

The integrated ReDiS system (Remote Diagnostic Ser-vice) has a direct online connection to the KHS ReDiS Ser-

vice Center for remote analysis. Managing director Horst

Kuhl says, With ReDiS we are on the safe side and can fall

back on fast KHS support at any time. This is important

for high line efficiency. And, of course, for a good tempo.

Another example: If the customer only wants to assemble

two different shrink packs, two or three conveyor sections

can handle identical shrink packs. In general, the new KHS

equipment enables up to four different shrink packs to be

combined in different ways on a single pallet. Individu-

al layer formations can be programmed and adapted to

changing retailers requests at any time. This means maxi-

mum flexibility.

Quick overview:

How he Innopal PBL sysem works.An inline robot grouping assembles the required forma-

tions for palletizing. The robots grip, turn, and move side-

clamped packs with millimeter accuracy and only minimal

space requirements. The gripper elements are lined with

plastic and are therefore suitable for processing sensitive

shrink packs.

The line operates with a combined layer and row

pusher. The layer pusher incorporated within the pal-

letizer also serves as a stop when the layer is discharged

onto the pallet. Extremely high palletizing accuracy of

the whole pallet structure is achieved thanks to a block

The trade requires widely differingshrink packs to be ready mixed andpositioned on a pallet.2

Innovaion


37/80

KHS competence:

Mr Kuhl, hand on heart, do you see a

long-term future for medium-sized mineral

water operations?

Horst Kuhl (laughs): Certainly! But only if the

companies position themselves in a targeted

manner. This includes top product quality, in-

novations based on market demand, and a

comprehensive, constantly improving service

package.

What role does technology play?A very big role. High-quality, flexible techni-

cal solutions that enable us to respond quickly

are essential. Before you ask: KHS offers such

technology and is therefore a key factor in our

positioning strategy.

How satisfied are you with the

new assembly line?

Highly satisfied, not least because it would be

impossible to achieve such quality and perfect

layer formation manually. A crucial aspect for

us is that the line offers scope for further au-

tomation, should retailers start asking for

even more sophisticated pallet assemblies.

What does the future have in store for

Mineralquellen Bad Liebenwerda?

Contrary to the current trend, in 2010 ourbrand products achieved around 5% sales

growth. For 2011 we expect similar growth.

Thanks to extensive expansion investment we

are well equipped for 200 million fillings. Im

happy for things to continue in this way.

Manuallyhis would beimpossible.Shor inerview wih Hors Kuhl, man-aing parner o Mineralquellen Bad

Liebenwerda.

+++ Company elegram +++

+++Mineralquellen Bad Liebenwerda +++

+++Member of the RhnSprudel group, which also includes Mineralbrunnen RhnSprudel, Spreequell, and Bauer Fruchtsaft GmbH +++

+++Among the 20 largest mineral water operations in Germany +++

+++40% of which these are conventional carbonated mineral water; 40% Bad Liebenwerda Medium; 20% Bad Liebenwerda Naturell +++

+++Mineral water accounts for 80% of fillings +++

+++ The RhnSprudel Group is among the top ten of the German mineral water industry+++

compeence 02.2011 /


38/80

Innoke 360 S: compac and efficien

THE SPACE SAVER processes 50,000 botles per hour

Innovaion


39/80

1. Compac and space-saving

The Innoket 360 S with a size

708 carousel is a compact

model. This machine needs

around 40% less space than

the Innoket 360.

2. Efficien and

cos-effecive

In the basic version of the

Innoket 360 S, the standard elec-

trical cabinet is paint-finished.

The station and centering hood

are adjusted manually. Hingeddoors offer adequate access and

CE-compliant machine protec-

tion for safe operation at up to

50,000 bottles per hour.

3. Fas and precise

The Innoket 360 S is quickly

ready for operation as a KHS in-

duction heater ensures short

heat-up times. Self-sharpening

cutters make sure that the la-

bels are always cut precisely. For-mat changeover is easy to un-

derstand, reproducible, and

fast, providing operational reli-

ability. Overlap correction takes

place during operation with-

out the system having to be

stopped. This ensures perfect la-

bel positioning.

4. Addiional opions

and benefis

The machine features the first

autosplice system that doesnt

need a costly, continuous supply

of compressed air. The segment-

ed vacuum drum makes change-overs simple. Motor-driven ad-

justment elements offer support

if changeovers are frequent.

Contact Oliver Kress | KHS GmbH, Dortmund, Germany | Phone: + 49 (231 ) 569-17 48 | Email: oliver.kress@k hs.com

Manfred Pschichholz | KHS GmbH, Dortmund | Phone: +49 (231 ) 569-1 513 | Email: m anred. pschich holz@kh s.com

The Innoke 360 S labeler exends he ried and esed KHS roll-ed range wih a

compac model. The basic package offers a echnical soluion a an atracive price,

wih modular exension packages available o sui demand. The key eaures

are described below.

Approx.16 m

Approx.25 m

35%

compeence 02.2011 /


40/80

QUANTUMLEAP

A deluxe shrink packer

Plus poins

The main new features of the new shrink

tunnel generation at a glance

Improved heating flow saves up to 15% energy

Savings package reduces energy consumption by

up to 20%

Gas heating saves up to 50% energy costs

Variable hot air nozzles

Even more gentle conveying

Automatic cleaning of the conveyor chains

Lighting and camera monitoring Six tunnel versions are available

Innovaion


41/80

KHS has made urher improvemens o no less han our modules in is

Innopack Kisers SP shrink packer or he beverage, ood, and non-ood indusries.

A new shrink unnel concep ensures significan energy and cos savings.

I allows shrink packs o be produced wihou shrinkage holes, has a pioneering

eaure whereby film can be prined on he inside o he pack, and an opion

o orm nesed packs.

future. All functions can easily be integrated, and energy

efficiency is a high priority. The twelve chief benefits of the

new shrink tunnel generation are described below.

1. Heaing sysem offers improved flow.

KHS has optimized the heating chamber by carrying out

a flow simulation. New ventilators ensure improved flow,

which saves up to 15% energy. Thanks to the optimized

flow, the number of ventilators and heating elements

have been reduced. For each possible shrink tunnel ver-

sion (see Page 45) only two instead of three heating cham-bers with one ventilator each are required. Additional

benefits include less servicing and fewer spare parts.

2. Energy-saving package: save up o 20%

An optional, additional energy-saving package offers po-

tential for saving up to 20% of energy.

Key benefit 1: a newly developed roller shutter system

that adjusts the product infeed and discharge openings

to suit the size of the pack during production and auto-

matically closes them when the packing machine stops.

This largely minimizes the escape of thermal energy.Key benefit 2: standby mode. The electronically con-

trolled standby function reduces the energy consumption

of all functional units involved in the shrink process to a

minimum. As soon as the production process calls for it,

all functions return to normal operation.

3. Environmenal bonus: opionalgas heaing available

The new concept includes an eco shrink tunnel with gas

heating instead conventional electric heating. In this way

The fully automatic Innopack Kisters SP shrink packerfor producing film-wrapped packs has been receivedenthusiastically. The Advanced product line offers modu-

lar packaging technology with tried-and-tested economic

efficiency and maximum flexibility. Yet things can get even

better. Based on requests from our customers, the KHS de-

velopment engineers have implemented significant tech-

nological improvements in four areas:

Shrink tunnel (with a whole range of optimizations),

Shrink wrapping of larger product formations

(now possible without shrinkage holes), Film printing (inside pack printing now possible), and

Variable secondary packaging (nested packs).

But first things first. Lets take a look at shrink packs. Its

hard to imagine life without them and they have long

since become popular worldwide, not least because they

support the impact of the brand at the point of sale. There

are two ways of doing this: with an unprinted film the

products make direct contact with the consumer. Printed

film communicates the advertising message with a diverse

range of options. In any case, the key for optimum presen-

tation of the brand is a perfect shrink result.This requires shrink technology that is well thought

out down to the last detail. And this is exactly where a lot

has been happening recently. KHS is now launching a new

shrink tunnel concept for the Innopack Kisters SP with re-

fined technology, a modified approach to the subject, and

100% practical orientation. The new Innopack Kisters SP

is a quantum leap for shrink packing; from a basic plat-

form the modular system can be configured and expand-

ed to specifically suit individual requirements. Moreover,

the new shrink tunnel concept, which KHS has standard-

ized for the Basic and Advanced product lines, is fit for the

compeence 02.2011 /


42/80

NEW (2)

Inside filmprining

KHS new online film printing setup integrates

film printing into the packaging prior to

the shrink process. Advantages: the online

print is on the inside of the pack / thermo-transfer printers make a perfect print /

optimum contrast, e.g. for barcodes / wide

range of print options (logos, additional

information, attractive images) / variable

print positioning and dimensions (width: 50 to

128 mm; length: up to 50 mm) / costs for

print material and paper labels saved / increased

machine availability / no handling required.

In practice, this results in even more safety,

ease of operation, machine availability, and

targeted cost reductions.

NEW (3)

Shrink packs wihnesed packs

The term nested packs refers to packaging

where the number of containers in adjacent

rows differs by one. Nested shifted packs

differ from nested packs in that each row hasthe same number of packs. In practice, this

results in improved stability of can, glass,

or PET packs. The film can be thinner and the

cardboard trays or pads that were previously

used are no longer required, thereby cutting

costs considerably, so that the additional in-

vestment will pay off quickly.

NEW (1)

Shrink packs wihoushrinkage holes

An alternative to nested packs and nested

shifted packs would be to invest in a manipu-

lating unit that can form classic shrink packs

without shrinkage holes. These packs have allthe advantages of nested packs and nested

shifted packs yet do not require any addition-

al investment in the pack conveyor and pal-

letizer section. In practice, the option to pro-

duce shrink packs without shrinkage holes

saves significant costs. The process uses less

material, increases pack stability, simplifies lo-

gistics and reduces stockholding. In addition,

only one material has to be disposed of when

the time comes.

Shrink packs without shrinkage holes are particularly stable and reduce costs.

1

2

3

Innovaion


43/80

7. Consan speed wih genle ransiions

While the tempo on the packaging machine varies accord-

ing to the production volume, in the shrink tunnel a con-

stant speed is crucial for a perfect shrink result. For this rea-

son a special functional unit has been installed between

the packaging machine and the shrink tunnel which com-

pensates for the difference in speed between these twomachine sections.

8. Auomaic cleaning o conveyor chains

Another optional module is an automatic cleaning system

for conveyor chains made of wire mesh. This system con-

sists of a counter-moving stainless steel brush located un-

derneath the conveyor chain which is engaged at fixed in-

tervals. Film debris and particles of dirt removed from the

conveyor chain are swept into a drawer that can be easily

emptied, thereby eliminating the need for time-consum-

ing manual shrink tunnel cleaning processes.

9. Lihing provides sae overview

Optional hood lighting gives operators a clear view of

the hood interior. This makes any fine adjustments to the

shrink process that have to be made by operators or main-

tenance personnel immediately visible.

10. Camera sysem or accurae monioring

A camera system can be installed at the shrink tunnel dis-

charge together with the lighting. This system transmitsimage files to a monitor installed next to the shrink tunnel.

Images can either be in black-and-white or color, depend-

ing on the option chosen. This has the advantage that op-

erators can conveniently observe the shrink process from

outside. An air curtain is used in place of the standard

hanging curtains in the shrink tunnel infeed and discharge.

11. Hygienic design makes cleaning simple

The cubic machine frame, already established in the Ad-

vanced series, provides even more space within the shrink

companies can save up to 50% of their energy costs, de-

pending on local energy prices. As an added environmen-

tal bonus the CO emissions are reduced by up to 60%.

Another important aspect is that a gas connection is suf-

ficient, without the need for air supply and extraction sys-

tems (chimneys).

4. Variable posiioning o ho air nozzles

Adjustable hot air nozzles give the best possible results for

each individual shrink pack. The air flow can be set exactly

as required to fully suit the individual pack format with re-

gard to both height and width. The amount of air required

for a perfect shrink result can be configured for each indi-

vidual nozzle, either manually or electronically using servo

motors. Nozzles can also be parked, a feature that proves

especially useful when a product program requires opera-

tion both in a single and in multiple lanes. This ensures that

hot air is always precisely directed to where it is needed.

5. Manual or elecronic orma changeover

The machine is set up manually for a different format by

means of spindles (standard). This is carried out accurate-

ly using digital displays and set-up documentation. As an

option, operator-guided format changeover offers signif-

icantly more convenience. The key points in brief: The op-

erator receives important information, such as when and

where an adjustment is to be carried out, at the control

desk (HMI) / Optimum overview of the changeover pro-

cess / All parameters are stored for every packaging for-

mat / Transfer to the electronic digital displays on the set-up units / Accurate reproducibility / Shrink tunnel hot air

nozzles adjusted fully automatically. The advantages in-

clude no troublesome paper lists / accurate reproducibil-

ity / reduced operator errors / smooth restart.

6. Toohed bel ensures reliable conveying

The type of conveying chain used i

Documents

Khs Competence 02-2011 Englisch Einzeln