Post on 02-Jun-2018
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
6/80
Inerview
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
19/80
2
compeence 02.2011 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
Capacity in the operating point:
50 to 60 Hertz / 8 to 12 kW
Possible output of vacuum pump:
16,500 liters per hour
Possible line output if one
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
Capacity in the operating point:
50 to 60 Hertz / 12 to 16 kW
Possible output of vacuum pumps:
25,000 liters/hr (2nd pump switches in*)
Possible line output if one
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 nski@khs.com
Innovaion
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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,
Bad Kreuznach, Germany
Phone: +49 (671) 852 -2501
Email: ludwig.cluesse rah@khs.com
Phone: +49 (671) 852 -2205
Email: michael.be isel@khs.com
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 rhoff@khs.com
Contact
Thomas Niehr
KHS GmbH,
Bad Kreuznach, Germany
Paul-Uwe Winterhoff
KHS GmbH,
Bad Kreuznach, Germany
As here is no overfill,
produc is saved.
compeence 02.2011 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 mping@khs.com
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
30/80
A RealAll-Rounder
Innovaion
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 r.deuschmann@khs.com
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
34/80
TEMPOTEMPO
T E M P O
Innovaion
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
36/80
Contact
Jrg Hoffmann
KHS GmbH, Dortmund,
Germany
Phone: +49 (231) 56 9 -1877
Email: joe rg.hoffmann@khs.com
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
38/80
Innoke 360 S: compac and efficien
THE SPACE SAVER processes 50,000 botles per hour
Innovaion
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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 /
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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
8/10/2019 Khs Competence 02-2011 Englisch Einzeln
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