02.

2012

Innovation 34 Service 52 Solutions for Sectors 64

Innofill Glass Micro: From old to new: Martens Brewery, Belgium:

fillers for up to 25,000 bph filler upgrades made to order the pioneers

Cans
are the future
Interview with Ball / High-tech filler technology / New packaging systems
Editorial

Prof. Dr.-Ing. Matthias Niemeyer

CEO/CTO, KHS GmbH Our innovations generate unique
features for both KHS and our
customers.
competence 02.2012 02/03

Ladies and Gentlemen:

Do you know that feeling when you realize that things are moving in the right direction, that
your plans, organization, and change processes are starting to bear fruit? Please dont get me
wrong; Im not basking in premature glory! However, here at KHS weve tackled a lot of issues
over the past year and done what we set out to do. The first big step has been taken.
In launching the eleven modules of the Fit4Future program, in the fall of 2011 we began
making long-term improvements. Intensifying customer relations and boosting our competi-
tiveness have the utmost priority here. Our goal is to build up strong, lasting partnerships; we
aim to reach this goal through leadership in the fields of technology and services, and have
made this strategy a composite part of KHS corporate vision.
KHS operates on a market that is bitterly contested worldwide. Despite this, weve noticed
considerable improvements in our results. Incoming and existing orders are well above our am-
bitious targets, as are capacities. The prospects for the current year are good.
With Fit4Future were on the right track, as with this program were not just cutting costs
but also undergoing a fundamental further development and shaping our own future. We will
carry on just as consistently as we started.

The prospects are good.

We can demonstrate this with the current issue of KHS competence, among other things. In it
well be presenting you with more innovations from our company, such as our little big machine
the Innofill Glass Micro that has been specially designed for small breweries and soft drinks bot-
tlers and features the twin-valve control a world innovation. Or the Innosept Asbofill ABF for
28-mm necks and the Innofill Glass filler which is now also being used in the wine, sparkling
wine, and spirits trade. Another focus of this issue is the can, that universal product which con-
tinues to be a real benchmark for KHS. Our innovations generate unique features for both
KHS and our customers.
Why dont you come and experience our innovative drive and most recent developments
at the upcoming Brau Beviale trade show? Brau Beviale in Nuremberg is traditionally one of the
most important beverage shows worldwide for the entire industry. Around 1,350 exhibitors and
a good 31,500 visitors are expected to attend this year. The show will take place from 13 to 15
November. Come and see for yourself were looking forward to seeing you there.

I wish you an exciting read!

Best regards,

Prof. Dr.-Ing. Matthias Niemeyer

Contents

06

The trend interview

06
Pure emotion
The beverage can is packed with emotion,
says Thomas Haensch, vice-president
for Sales, Marketing & Innovation at Ball
Packaging Europe

The can in focus The can in focus

12
KHS canning technology
Main feature  Page 1231 Up to 120,000 cans per hour

14
The flexible machine
Bavaria Brewery has a KHS canning line
that can process (almost) anything
Seventy-seven isnt old at least not for the beverage
can. It first appeared on the market in 1935 as a tinplate 20
container weighing 100 grams. Since then it has risen The standardizers
How Carlsberg has brought its can packing
to success the world over. And it has a great future
lines into line
in store. Find out what this could hold in our interview
with Ball manager Thomas Haensch. Also, three best- 26
The lucky charm
practice studies illustrate how KHS customers with
Sabeco in Vietnam now has its ninth canning
vision have found out how to get the best from their cans line from KHS. And not without good reason
economically and ecologically and regarding
proximity to the market.
competence 02.2012 04/05

42 58 76

Innovation Service Special

Topic overview: innovations that will make
you more competitive
34
Little big machine
The Innofill Glass Micro especially for small
breweries and soft drinks bottlers
38
The best system for the best vintages
The innovative Innofill Glass filler
now also for the wine, sparkling wine,
and spirits sector
42
Better Basic
The Innopack Kisters Basic series is now
optimized for the low capacity range
46
Specifically for fruit juices
The linear Innosept Asbofill ABF now
for 28-mm necks
52 76
New from old: LED the light of the future
filler upgrades to order Innovative LED technology is already
How beverage plants can profit from filler creating added value for companies
conversions. A revolutionary survey in many fields. Read more about the
light of the future
Solutions for Sectors
In-house News
58
Good Morning, Vietnam 82
Japanese Sapporo Group puts three KHS Brau Beviale preview
turnkey lines into operation in Vietnam In Nuremberg guests to the KHS booth can
look forward to a multitude of innovations
64
The pioneers 84
Martens Brewery, Belgium, turns technologi- 50 years of KHS Brazil / New KHS factory
cal benefits into a competitive advantage in China / KHS Press Circle / New produc-
tion shop for KHS Corpoplast / Trade show
68 review: Mexico / 50 years at KHS / Awards
for KHS competence / KHS and the Olym-
A milestone
pics / KHS on YouTube
Rmerquelle in Austria centralizes its
News from KHS
activities. First step: a KHS ultraclean filler

72 87
Market Report A combined system for kegs KHS competence
Efficiency is tops: HEINEKEN invests in the Publishers information and
48 KHS Innokeg Till One4Two system plant addresses
Spendrups Bryggeri / JSC Georgian
Beer Company / Brouwerij Haacht /
Molkerei Imlek / JW Lees / Lakefront
Brewery / Delta Beverages /
Coca-Cola Canners
Customer projects and KHS acceptance
tests around the globe
Interview
competence 02.2012 06/07

pure
E motion
The can in focus / In the following interview with KHS Competence
Thomas Haensch, vice-president of Sales, Marketing & Innovation
at Ball Packaging Europe, explains how beverage companies can and
will continue to profit from the global success of the beverage can,
outlining the design options it currently has, how sustainable it can
be, and which emotions are associated with it.

KHS competence: Mr. Haensch, what do you think are

the major advantages of the beverage can?
Thomas Haensch: Cans are light and easy to transport,
can be quickly chilled, are completely impervious to light
and oxygen, and thus conserve the quality and freshness
of their contents for a particularly long period. They are
also versatile in their design, making them especially in-
teresting as far as marketing is concerned. And they have
proved to be a sustainable lightweight. Tin cans holding
0.33 liters weigh about 22 grams today, with 0.33-liter alu-
minum cans weighing in at around 10 grams. What a lot
of people dont know is that the beverage can is currently
the most frequently recycled type of beverage packaging
in the world. Its not only 100% reusable but can also be
remanufactured with no loss of quality whatsoever. This
means that every old can can make a new one.
Interview
Whether sight, touch, smell,
or taste the can is able to
appeal to practically all of our
senses.
The trend interview
In its previous few issues KHS com-
petence ran a series of articles enti-
tled Trend Interviews that were in-
tended to give readers added value
in practice. Talks with qualified ex-
perts were designed to provide an in-
sight into future developments on
our global markets, and in the bever-
age, food, and non-food industries in
particular.
Thomas Haensch
Vice-president of Sales, Marketing & Innovation,
Ball Packaging Europe
The first interviews held by In this issue a man who knows
KHS competence were everything about beverage cans
has his say:
with Professor Peter Wipper-
mann, one of the guiding lights in Thomas Haensch, vice-president of
trend-related market research, on the Sales, Marketing & Innovation at Ball
general tendencies in the beverage Packaging Europe. A look into the
and food industries, and future: the can in focus.
with Fred Piercy, business direc-
tor for wines and spirits at the larg-
est global packaging company listed
on the stock exchange, Amcor Rigid
Plastics, on the trend for wine in PET
bottles.
competence 02.2012
Are young people the main target group?
Were seeing a growth in the use of the beverage can
across all age groups. However, its true to say that the
consumption of beverages in cans is highest in a young-
er target group, and that here, too, growth is the largest.
This is probably also because many young beverages are
quite consciously marketed in cans. Im thinking of ener-
gy drinks, for instance; over 60% of all energy drinks in Eu-
rope now reach the consumer in cans. This figure is about
10% for classic soft drinks. If you look at the beer segment,
around 20% of all beer made in Europe is sold to the con-
sumer cans.
Is the can not also a container thats associated with
youth, meaning an older target group can use it to show
that theyve stayed young?
Thats right. This is just one of the many emotional sides
to the beverage can. In my option, the beverage can is
packed with emotion. Youthfulness, freedom, conveni-
ence, coolness, freshness, and being active are surely all
included. These emotions can be made even stronger by
an individual can design thats specifically based on the
brand strategy of the particular company.
What individual design options are there?
We have a number of individual design options for the
beverage can which we split into three categories. The first
of these is the cans shape and size. Besides the classic var-
iations we also have access to other formats, such as the
sleek, slim, or handy can. The second category is the design
of the can exterior. Digital printing, embossed cans, and
We believe that the Asian market holds the
most promise for beverage can growth.
08/09
matte can finishes are just some of the many conceivable
designs. By applying special prints, such as QR codes, con-
sumers can also be involved in promotional activities. The
third area concerns the can closure. Incidentally, in 2008
Ball introduced the first resealable can to market. We be-
lieve that this finally makes us even with the many advan-
tages provided by the bottle. There are other options, too,
such as cans that give off a fragrance, like a cranberry fra-
grance for a cranberry beverage, for instance. Thats now
perfectly feasible.
Or swimming capsules integrated into the can,
whose contents are released when the can is opened.
These could be vitamins, minerals, or other substances
that are always freshly mixed into the beverage. Whether
sight, touch, smell, or taste the can is able to appeal to
practically all of our senses.
The can appeals to our senses.
Do you envisage an increased individualization
of the can?
The trend is clearly moving towards individual design, and
thus differentiation and targeted brand communication.
By the way, as were fully aware of this trend, weve now
set up what we call a Can School.
All interested customers can sign up and profit from
talks on the beverage can market, new marketing oppor-
tunities, and the most recent technical developments,
among other things. At this point Id like to mention that
Interview
In the preliminary stages of
development we work with partners
such as KHS.
Embossed design elements
you can feel make for a
truly gripping style of can.
its very important for us not to go it alone when it comes
to new developments. In the preliminary stages of de-
velopment we work with partners such as KHS, the spe-
cialist for filling and packaging technology. This enables
us to ascertain whether proposed innovations are suit-
able for practical use in all respects before theyre ready
for market.
What role does the aluminum bottle play?
The aluminum bottle is an outstanding individual design
option and also a fantastic way of underlining the premi-
um characteristics of a beverage. Im convinced that it will
have a great future in store when ways are found of fur-
ther reducing its wall thickness and weight.
What about beverages like wine, sparkling wine, and
spirits? Can the can establish itself in these segments?
Generally speaking, theres not a beverage I cant see be-
ing filled in cans. As far as wine, sparkling wine, and spirits
are concerned, I think we have a great chance of reaching
new target groups with the can. I believe that typical wine
drinkers will hardly be convinced by wine sold in cans. Yet
young adults who consider wine to be more of a tradi-
tional beverage may find it cool to drink wine from a can.
The Bembel With Care brand demonstrates that it is actu-
ally possible to successfully gain new target groups with
a beverage thats usually associated more with tradition-
al values. Bembel With Care aims to have people drinking
cider from the can, with the range including cider, cider
with cola, and a cider spritzer. Launched to market in
2009, the goal of the product is to redefine German cider
or Apfelwein and move it away from its traditional image.
Bembel With Care is now listed in trade and is a fixed fea-
ture on the fashionable catering scene in the federal state
of Hesse. Its website focuses on lifestyle, and includes a
shop selling everything the cider fan could possibly desire,
and a photo gallery depicting fans with their Bembel With
Care cans in various places around the globe.
Youve used an example from Germany. The German
beverage can market was and is still very much
affected by the obligatory deposit levied on all one-way
beverage packaging in 2003. Do you think a renaissance
of the beverage can is possible in Germany in the
medium to long term?
After the deposit law was introduced, the German bever-
age can market crashed by about 90% which at the time
was really crucial.
However, were convinced that therell also be fur-
ther growth in Germany. In the past three years the per-
centage of beverage can sales in Germany went into two
digits, and in 2011 it again rose to over a billion cans for
competence 02.2012 10/11

The company
Ball Corporation headquartered in
Broomfield, Colorado, was found-
ed in 1880 as a small-scale manu-
facturer of wood-jacketed cans. It is
now a leading international packag-
ing company whose core business is
beverage and food packaging. With
approximately 14,500 employees
and 64 sites worldwide, Ball Corpo-
ration realized annual sales of $8.6
billion (approximately 6.5 billion).
Ball Packaging Europe is one of the
leading manufacturers of bever-
age cans and aerosol packaging in
Europe. The company runs twelve
beverage canning plants that em-
ploy 2,800 people. The regional
headquarters are in Ratingen, Ger-
many. Yearly sales amount to ap-
proximately $2 billion (1.5 billion).

the first time in many years. As we see it, in the next few
years this figure should climb to over two billion bever-
age cans a year.
Whats canned beverage consumption like worldwide
and where do you see a particularly large potential for
growth in the future?
The USA is top of the list, where the average per capita
consumption is 290 cans per year. This number is hard to
beat! In all other regions of the world were expecting fur-
ther growth. In Europe we think that this growth in per-
cent will only be in the single-digit range. In Asia, Africa,
the Middle East, and South America, on the other hand,
we think two-digit percentages are perfectly feasible. We
find that the Asian market holds the most promise at the
moment. It could draw level with the American market in
the next few years and top the 100-billion-can mark.
in materials are just as much in focus as new printing tech-
niques and closure systems here. Individual can design will
also remain an important topic. Providing our customers
with an individual consultancy service is also of prime im-
portance. This includes giving advice on marketing and
innovation as well as more general services, which we al-
ready provide at our research and development center.
Should our customers opt for a new type of beverage can,
we fill test batches under realistic, practical conditions.
These tests concentrate on two key issues: How does the
liquid behave in the beverage can? And does the container
stay neutral enough so as not to affect the taste of the
filled product? Its good that we have partners like KHS at
our side for these practical trials, and that were thus able
to provide the beverage industry with expertise that is
fully comprehensive in all respects. Its precisely this which
will count in the future.

What measures would you like to use to secure the

beverage can as positive a future as possible?
We shall continue to drive innovation forward under the
aspect of environmentally friendliness and the added
value the beverage can is able to give the consumer. This
is firstly to make the sustainability of the beverage can Mr. Haensch, thanks very much for
more of a foreground concern, and secondly to remain showing us the future.
competitive with other containers on the market. Savings The interviewer was Friederike Arndt
The can in focus

The can in focus Page 1231

KHS canning technology

Up to 120,000 cans per hour

Even for high-performance canning lines, turnkey supplier KHS is a global

leader. These lines are designed to output up to 120,000 cans per hour.
The graphic on the right shows the main features and advantages of the chief
KHS machines on such lines. One of the highlights is FullyEnclosed FilmPack
technology that produces attractive, stable, large-format shrink packs.
The following pages give three best-practice examples of successful KHS can-
ning technology at Bavaria Brewery, Carlsberg, and Sabeco Brewery.
competence 02.2012 12/13

Technical features: Electronically controlled / electromagnetic inductive flow metering /

Filling
aseptic membrane and seal technology
The Innofill DVD
Advantages: For both still and carbonated beverages / top filling accuracies / especially
volumetric filler
low-oxygen filling process / easy changeover to different can types

Technical features: Container dimensions / modular design / dynamic PU control

Pasteurizing
Advantages: Simple to transport / quick to install / optimized pasteurization /
The Innopas C fast reaction to new products / optional EcoBus or Economical Buffer System for energy
pasteurizer concept and water savings

Technical features: Modular design / cubic machine frame and protective hood
concept / gapless support systems for the function modules / up to four servo drives /
Packing new film cutting and feed system / optional fully automatic adjustment /
The Innopack Kisters shrink tunnel with energy-saving gas heater
tray packer, shrink packer, Advantages: Maximum flexibility / simple, fast, unlimited changeover /
tray shrink packer, optimum accessibility with perfect view of machine interior / extremely hygienic /
pad shrink packer, and processes extremely thin films
wrap-around packer NEW: The FullyEnclosed FilmPack for large-format shrink packs provides
stable and attractive secondary packaging / potential savings without trays or pads /
no displacement of containers / handles or tear-off sections possible

Technical features: Innopal ASH Lifts pallets to respective pushoff positions /

Palletizing important surfaces covered in plastic sheeting / automatic pallet liner remover for cover
frames and pallet liners
The Innopal ASH
Innopal PB1HS Upstream inline robot grouping / pallet elevator when split loading
can depalletizer and
plates are used
the Innopal PB1HS
Advantages: Innopal ASH Gentle depalletizing by removing the cans layer
palletizer
by layer / Innopal PB1HS Packs aligned in the minimum amount of space / gentle
loading onto pallets
The can in focus

The can in focus (I)

The flexible
machine
The Innofill DVD volumetric filler processes cans from various
manufacturers with maximum filling accuracy and flexibility
competence 02.2012
A KHS canning line is in operation in the Netherlands that can process an entire
range of beverages and products / Bavaria Brewery, a traditional family company
in Lieshout, distributes to over 100 countries throughout the world, and has been
relying on KHS technology and service for 25 years. The new canning line is extremely
flexible and gives the client maximum quality and sustainability.
I t all started in 1719 with about 14,000 liters of beer per
year when Laurentius Moorees founded village brew-
ery Bavaria in Lieshout in Noord-Brabant in the south of
the Netherlands. Production only really took off under
the management of Jan Swinkels, the company founders
great-grandson. The Swinkels family now runs the busi-
ness in its seventh generation together with one other
partner, and as the second largest brewery in the Nether-
lands it produces around six million hectoliters a year, dis-
tributing its beer brands which include Bavaria and Hol-
landia non-alcoholic beverages, still water, and energy
drinks to more than 100 countries worldwide.
This is a great achievement for a family firm a feat
CEO Jan-Renier Swinkels is well aware of. Were proud
that Bavaria Brewery has stayed in the family for genera-
tions. The owners find engineering design that encourag-
es our pioneering spirit and allows us to react to new chal-
lenges with great speed just as important. And this is why
the family has relied on technology from KHS since 1987.
The first KHS product to prove totally convincing was
Innopack Kisters packaging technology. Bavaria Brouwerij
now operates 20 KHS packaging machines. In 2000 the
14/15
brewery invested in its first KHS pasteurizer; four are now
in operation. In 2009 the biggest order in the companys
history went to KHS for a turnkey canning line with a ca-
pacity of up to 75,000 cans an hour, three can depalletiz-
ers, and two new glass bulk depalletizers.
Just recently the company ordered another turnkey
canning line from KHS that is able fill up to 90,000 cans per
hour. Jan-Renier Swinkels is extremely satisfied. We value
the high quality of KHS technology and also the great flex-
ibility and sustainability KHS systems give us. At the same
Beer and much more
time were profiting from a consultancy service thats very
hard to beat. This includes the logistics concept KHS is cur-
rently working on with Bavaria, for instance, that will re-
place forklift traffic in the production shop with driverless
transport systems.
But lets get back to the canning line. Its worth hav-
ing a look at the main components of this line and at the
benefits these hold for Bavaria Brouwerij. For example,
the line not only cans beer but also still and carbonat-
ed alcohol-free beverages. It also currently processes 50
different styles of a widest range of can sizes including
150, 200, and 250-ml slim cans and 330, 440, and 500-ml
standard cans.
The can in focus


 competence 02.2012 16/17

The heart of the line is the Innofill DVD with KHS turnkey canning line fills beer,
top filling precision and an output of 90,000 and still and carbonated alcohol-free beverages.
cans per hour.

The benefits of the Innopal ASH depalletizing robot

+ A pusher system enclosed on four sides centers each
layer, ensuring gentle depalletizing. Plastic sheeting also
protects the product.

The benefits of the Innofill DVD volumetric filler

+ The heart of the line, the electronically controlled
Innofill DVD volumetric filler equipped with 124 filling
stations and electromagnetic inductive flow metering,
stands for top filling accuracy. The fact that Bavaria fills
various cans types is thus not an issue here.
+ Flexibility is required. The machine is thus converted
when can sizes are changed at the push of a button on
the operator panel. This saves time and boosts machine
availability. Normal format part changing is necessary only
if cans with other diameters are to be processed.
Product manager Hans van Vijfeijken and project
manager Peter Korsten agree that The Innofill DVD is a
very flexible, extremely hygienic filling system that at the
same time gives us that so very essential low oxygen fill-
ing process. It fully meets our high expectations of prod- + The brewery also saves water as the system feeds the
uct quality. pasteurizer buffer tanks with collected rinse water.
+ Thanks to KHS PU control that reliably kills germs and
The benefits of the EcoBus process stabilizes flavors, new products or new can styles can be
+ An Innopas PII SC double-deck pasteurizer based on the quickly integrated into the pasteurizing process later in
EcoBus or Economical Buffer System handles the task of the process which again results in maximum flexibility.
pasteurizing the filled cans. The pasteurizer works with Hans van Vijfeijken is convinced. On our first invest-
three buffer tanks. As these buffer tanks are designed to ment in KHS pasteurization technology in 2000 we imme-
hold hot, warm, and cold water, both heating and cooling diately recognized the many advantages this could give
energy can be temporarily stored and reintroduced to the us. It was therefore only logical that we should continue
process at a later stage. to make use of such benefits.
Thumbnail portrait:
Bavaria Brouwerij
Founded 1719
Site Lieshout, the Netherlands
Annual sales 6 million hectoliters
Export To over 100 countries
Portfolio Beer (such as Bavaria and Hollandia), still water,
and energy drinks
Facts Second largest brewery in the country,
family-run company in its seventh generation

Collaboration with KHS: Since 1987

(20 packers, pasteurization technology, and canning technology with
capacities of up to 90,000 cans per hour)
competence 02.2012 18/19

The benefits of Advanced packaging technology

+ An Innopack Kisters SP Advanced shrink packer current-
ly packs 4 to 15-can packs in six different can formations.
+ The Innopack Kisters TSP Advanced tray shrink packer
turns shrink pack formations into tray or pad shrink packs,
and processes loose cans in 50 different types of pack.
+ Operator-prompted format changeover in place of the
manual system eliminates the need for checking all areas
where adjustments may be necessary.
+ Where possible toothed belts are used for a simple de-
sign and quiet, maintenance-free operation.
+ Another major advantages include identical servo mo-
tor with integrated servo controllers, easing replacement
if maintenance is required, and reducing the stock of spare
parts.
+ The film cutting and feed system processes very thin film.
An additional antistatic system provides maximum feed
stability, even for very sensitive film types. The film cutter
with its separate servo drive works independently of the
main drive, giving a top precision cut with minimum wear
on the cutters.

The benefits of the ECO shrink tunnel All told, KHS has again given
+ The ECO shrink tunnel Bavaria opted for this innova-
tion on both packers operates with gas heating instead
us a turnkey canning line that
of the conventional electric heater. Energy savings of up to leaves absolutely nothing to
50% are possible. The usual chimney is also not required.
Project manager Korsten makes a few calculations.
be desired. This system is also
By using this concept were reducing our energy costs in perfect accord with our
in the long term. We also greatly appreciate the fact that
compared to the classic shrink tunnel with electric heat- strategy of quality, flexibility,
ing were able to cut our CO emissions by around 60%. and sustainability.
Jan-Renier Swinkels sums up. All told, KHS has again
given us a turnkey canning line that leaves absolutely
nothing to be desired. This system is also in perfect accord Jan-Renier Swinkels
with our strategy of quality, flexibility, and sustainability. CEO of Bavaria Brouwerij

Contact
Edgar-George Petsche Phone: +49 (671) 852-2514
KHS GmbH, Bad Kreuznach, Email: edgar.petsche@khs.com
Germany

Katrin Goldhahn Phone: +43 (2236) 62-510

KHS Austria GmbH, Wiener Email: katrin.goldhahn@khs.com
Neudorf
The can in focus
competence 02.2012 20/21

The can in focus (II)

The standardizers
The Carlsberg Group standardizes its canning line packaging systems / The
implementation of this challenging task at three sites in Northern and Western
Europe was entrusted to KHS who supplied the design engineering, consultan-
cy, and a whole host of services that fulfilled all requirements. The result is total
flexibility for the customer.

C arlsberg knows what the beverage market wants: the best prod-
The KHS Innopack Kisters SP
Advanced shrink packer: view
of the grouping station
ucts for its money, of course, but also striking packaging that at-
tractively presents the container at the point of sale so that it makes
a lasting impression. With its recent investment in packaging tech-
nology the fourth largest brewery group in the world added yet an-
other criteria, namely that the technical equipment should be de-
signed so that three of the companys main facilities can manufacture
all of the can packaging formats required in Northern and Western
Europe and therefore flexibly distribute production orders between
the three plants.
Peter Nilsson, vice-president of Customer Supply Chain Europe at
Carlsberg, names the sites involved and outlines the results. Standard-
ization was a central concern of the packaging lines recently installed
at our production plants in Fredericia in Denmark, Kerava in Finland,
and Gjellersen in Norway. Together with KHS we thus worked out
a specific packaging concept. We now have identical packaging vari-
ants for these sites, giving us more flexibility and sustainable operation
while cutting costs with absolutely top quality.
Carlsbergs standardization program utilizes ultramodern KHS
turnkey packaging lines comprising three components:
The can in focus

the Innopack Kisters SP Advanced shrink packer,
the Innopack Kisters TSP Advanced tray shrink
packer, and
the KHS Innopal PB 1 HS palletizing concept with
integrated robot grouping technology.
With these newly established packaging machines, at all
three plants Carlsberg can either pack the finished cans in
small-unit shrink packs of 4 to 10 cans each, and/or in tray
or pad shrink packs. There are also other options available
(see New options for Carlsberg on page 23).
The packaging lines are of course tailored to suit the con-
ditions prevalent at each individual site. Praises Nilsson,
KHS devised layouts for each site which took the require-
ments of each existing canning line into account. There
were plenty of animated discussions and comprehensive
consultancy sessions before the general concept was fin-
ished, without which the final result would not have been
possible. For example, numerous tests were carried out
with the designated pack options using various packag-
ing materials at the KHS plant in Kleve. Packaging work-
shops were also specially organized for the people at
Carlsberg, where KHS experts and specialist film manufac-
turers knowledgably presented their expertise. All told,
states Nilsson, KHS offered us a full consultancy package
and demonstrated a field of competence that is unique
to the market, all of which the entire Carlsberg Group is
profiting from.

Three packaging lines for

Carlsberg from KHS

In Fredericia and Gjellersen the packaging lines process

1 72,000 0.33-liter cans an hour and are installed down-

stream of an existing canning line. In Finland KHS packag-
ing technology is connected to two existing canning lines
that output 72,000 and 90,000 0.33-liter cans per hour.

Practical example: the packaging system

in Fredericia
The system now up and running at the Danish plant in
Fredericia is used here as an example to illustrate the con-
struction and operation of KHS packaging concept for
Carlsberg.

2 + Small formations (four to ten-unit packs). Loose cans

destined for shrink packs are sent to the multiple-lane
Innopack Kisters SP Advanced shrink packer immediate-
ly after filling and pasteurization. The shrink packs then
either pass through a handle applicator and are sent

1. The FullyEnclosed FilmPack

2. The Innopack Kisters shrink packer
3. Film wrapping
3
competence 02.2012 22/23

Before
Smaller Wrap-around
can formations cartons

Now

Shrink packs

Tray shrink packs

Pad shrink packs

Application of an
optional handle

Before
Larger Tray shrink
can formations packs

New options for Carlsberg

Cutting-edge KHS packaging technology is installed
downstream of existing canning lines at the three Carls-
berg sites. The specific challenge for KHS was that all
packaging lines should be able to process all types of pack
at all three plants.

The chief benefits

Packaging costs are considerably reduced
(particularly for small formations).
Printed film packs are more attractive than
wrap-around packs.
The can in focus

We now have identical packaging variants [],

giving us more flexibility and sustainable operation
while cutting costs with absolutely top quality.
Peter Nilsson
Vice-president of Customer Supply Chain Europe at Carlsberg

straight on to the palletizer, or they are conveyed to the

Innopack Kisters TSP Advanced tray shrink packer which
places a specified number of shrink packs in either tray-
and-film, pad-and-film, or film-only packs.
+ Large formations (12 to 32-unit packs). Loose cans are
transported to the Innopack Kisters TSP Advanced where
they are turned into tray, pad, or shrink packs.
+ The FullyEnclosed FilmPackTM option. KHS patented
FullyEnclosed FilmPackTM option is integrated into the
Innopack Kisters TSP Advanced. This produces shrink
packs without bulls eyes and with the following advan-
tages: shrink packs remain stable, however large, the cans
arent displaced, the packs can be safely transported by
the applied carrying handle, and savings can be made as
trays and pads are no longer needed.
At the moment were testing consumer acceptance
of the fully-enclosed film pack on the Danish market, Nils-
son reveals. If we get a positive response, this option can
be quickly retrofitted at other Carlsberg sites that have re-
cently installed KHS packaging machines.
+ High-performance palletizer. The Innopal PB 1 HS high-
performance palletizer is installed directly upstream of an
inline robot grouping station. The advantages here are
the minimum space requirements, top precision, exact re-
producibility, precise alignment, extremely gentle pack
handling, easy selection of either existing layer formations
or new container and layer configurations, and the utili-
zation of euro, half, and quarter pallets, including pallets
with wheels.
Niels Sogaard, project engineer, and Christian Malm-
strom, project manager, both at Carlsberg in Fredericia,
are in complete agreement. KHS has done a fine job.
Were just as pleased with how the project has gone as we
are with the result. We also greatly appreciate the fact that
after a very fast commissioning phase for the new packag-
ing line KHS placed an engineer at our disposal for several
months who was able to answer any questions our em-
ployees had.
With such satisfaction being expressed, it comes as
no surprise to learn that KHS recently received three more
orders from Carlsberg for can packaging concepts for the
plants at Okocim in Poland, Saku in Estonia, and Lbz in
Germany. Standardization of our packaging technology
is by no means finished once the three new lines are in op-
eration, states vice-president Nilsson. What we want to
do is provide our customers with the attractive packaging
options they require anytime, anywhere. And we hope
this strategy will help us come closer to our goal of being
the fastest growing brewery group in the world. As al-
ready said, Carlsberg knows what the market wants.
Contact
Volker Borngrber
KHS GmbH, Dortmund, Phone: +49 (231) 569-1669
Germany Email: volker.borngraeber@khs.com
Ralph Pohl Phone: +49 (231) 569-1383
KHS GmbH, Dortmund, Email: ralph.pohl@khs.com
Germany
competence 02.2012 24/25

Spotlight: innovative
Advanced technology
+ Hygienic protective hood concept
+ Improved operator viewing
+ Optimum accessibility for maintenance
+ Special concept ensures maximum hygiene
+O
 perator-prompted format changeover with an electronic display
can be optionally included
+S
 hortest possible downtimes for format changeover
(Carlsberg processes 20 varieties of pack)
+E
 xtremely thin film of up to 25 m can be processed, saving costs
+S
 pecial film cutting and feed system for the perfect positioning
of various film widths
+H
 ole patterns automatically discharge static electricity; in conjunction
with an antistatic system, this provides maximum conveying stability even
for extremely delicate films
+T
 he film wrapping process is precision adjusted to the product height
and length
+ F ilm is cut with a servo-driven cutter
+ The FullyEnclosed FilmPack option can be integrated.

Thumbnail portrait: Carlsberg Group

Founded 1847
Fourth largest brewery group worldwide
Output in 2011 119 million hectoliters

Over 500 brand products in over 140 countries

International premium brands: Carlsberg, Tuborg,
Baltika, Kronenbourg 1664
Strong national brands include Ringnes (Norway),
Feldschlsschen (Switzerland), Lav (Serbia), and Wusu (China)
40% of Group sales attributable to Northern and Western Europe.
The can in focus

Sabeco: also taking the

booming Vietnamese beer
market by storm with
Sagota, one of the companys
five brands.
 26/27

The can in focus (III)

The lucky charm

KHS has installed the ninth high-tech can-

ning line at Sabeco, Vietnams chief brewery
group / The number nine is a lucky number,
say the locals who continue to follow the
unbelievable success story of their showpiece
brewery. With the latest canning technology,
KHS has long played an integral part.

A booming market usually starts with a vision. And with a visionary

who believes in his idea and puts all his energy into its implemen-
tation. For the Vietnamese beer market, this go-getter with the gold-
en touch is called Van Thanh Liem. Like no other, Liem is something
of a pioneer; as chairman of Sabeco Trading Co. Ltd (Sabeco) he start-
ed canning beer for the first time in 2007 on a KHS turnkey canning
line, no less. Today, the company has nine KHS canning lines with a to-
tal capacity of 230,000 0.33-liter cans per hour working in three-shift
operation throughout.
Van Thanh Liem has since become vice-president of the Vietnam
Beer Alcohol Beverage Association (VBA), and continues to be an out-
standing connoisseur of the Vietnamese market for cold beer. Our
beer market will grow particularly strongly in the future, as up to now
people in rural areas consume relatively little beer, predicts Liem. I see
enormous potential for growth here. This is confirmed by the figures.
The per capita beer consumption was just 10 liters per annum at the
turn of the millennium; by 2006 it had reached 18 liters, and the cur-
rent amount is 28 liters.
The can in focus


 competence 02.2012 28/29

The proportion of cans could

reach 50% by 2015. And
this means being ready for it.
Van Thanh Liem
Vice-president of the Vietnam Beer Alcohol Beverage Association (VBA)
and former chairman of Sabeco Trading Co. Ltd (Sabeco).

The KHS Innopack SP single-column packer

packs cans in cartons.

A percentage growth in double figures is forecast. By

2025, the total beer consumption in Vietnam is expected
to be around 70 million hectoliters; today this statistic is al-
ready at approximately 25 million hectoliters. This extraor-
dinary boom is largely thanks to canned beer. Around 30%
of beer is currently sold in cans, and more than 40 ultra-
modern KHS lines are running at different companies
throughout the country (including 90% of all canning sys-
tems in Vietnam).
At the center of this extraordinary happening is
Sabeco. In 1996 the company had only one brewery with
an output of 160,000 hectoliters. By 2005 this had in-
creased to three breweries with a capacity of 300,000
hectoliters per year. In 2012 the group owns 27 breweries
with an output of 12 million hectoliters (there are around
60 breweries in the country altogether). In addition,
Sabeco has two plants for other alcoholic beverages and
one for carbonated soft drinks. Sabeco produces five
brands of beer: Saigon, Saigon Export, Saigon Special,
333, and Sagota. Containers range from 0.33, 0.355, and
0.45-liter glass bottles to 0.33-liter cans.
An interesting fact is that with the recently intro-
duced Sagota brand, Sabeco has quite specifically taken
a step in the direction of the premium beer sector. Our
main target group in the future will continue to be the
middle classes with young adults, says Liem. However,
were also seeing an increasing demand for premium beer
in Vietnam. The company also hopes to benefit from the
continuing, rapidly increasing popularity of the can. The
proportion of cans could reach 50% by 2015, says Liem.
And this means being ready for it. Reasons for the boom
in cans are the high level of convenience (cans are easy
to carry and dispose of, with no returns as with refillable
bottles), the fact that they are tamperproof, and that they
symbolize the Western lifestyle we can treat ourselves to
something special.
Van Than Liem has the highest praise for KHS can-
ning lines. We started canning using KHS technology.
This gave us the reliability necessary for the best quality
beer. As weve had such good experience with KHS, weve
remained faithful to our trusted supplier over the years.
The latest canning line is up and running in the Binh-Tay
Brewery, Ho Chi Minh City. With a capacity of up to 33,000
cans per hour, it produces at high efficiency virtually right
around the clock. Along with outstanding KHS filling and
packaging technology, perfect service is very important
to us, says Liem. KHS Vietnam is exemplary in this re-
gard. The reason behind this is that more than 30 KHS
service engineers based in Vietnam are at the customers
beck and call 24/7. In addition, if the worst comes to the
worst, the local KHS agent can obtain spare parts quick-
ly and easily.
The special features of the new KHS canning line in
Ho Chi Minh City are:
1. Perfect filling system
The Innofill DVD filling system ensures the highest fill-
ing accuracy, tolerates cans from different manufacturers,
The can in focus
provides aseptic membrane and sealing technology, and
works with low foam and oxygen.
2. Modern PU control
The Innopas PI SC single-deck pasteurizer with integral PU
control ensures the full flavor of the product, and reduces
energy and water consumption to a minimum. Its most
important that we reliably destroy any germs while at the
same time retaining the full flavor stability of our quality
beers," says Liem.
3. Sophisticated packaging concept
After re-inspection and coding of the cans, the Innopack
SP single-column packer packs the cans into cartons. Spe-
cial characteristics include outstanding accessibility, fast
format changes, and simple operation. Upstream is the
Innopack CA carton opener. This sets up folded card-
board box blanks, folds in their bottom flaps, and glues
them with hot melt. The system adapts to different carton
sizes quickly and easily, resulting in short changeover
times and reliable startup. Finally, the Innopack CV carton
sealer ensures flawless glue application and perfect seal-
ing without deformation of the carton.
4. Optimized palletizing
A special feature of the Innopal PBL1N1 column-type
robot is level compensation by means of an elongated
layer pusher extended in the direction of the full can
conveyer. This means that the layer pusher also acts as a
row pusher, setting up layer formations and palletizing
simultaneously.
5. Informative Plant Monitoring System (PMS)
The Plant Monitoring System or PMS, a PC-assisted data
acquisition system, monitors all stations on the line.
Fast identification of weaknesses and faults increases
competence 02.2012 30/31

Thumbnail portrait:
Sabeco
Vietnams number one brewery

Group 27 plants
Output in 1996 160,000 hectoliters
Output in 2012 About 12 million hectoliters
Export To 22 countries

Main beer brands 333 and Saigon Export

Premium beer Sagota
First KHS canning line 2007
Ninth KHS canning line 2011

LEFT The KHS Innopas

PI SC and KHS Innofill DVD
form the heart of the new
KHS turnkey canning line at
Sabeco.
RIGHT Reliable and
on the spot: KHS service
engineers.

productivity. Seamless documentation of process values

and energy and media consumption aids quality assur-
ance and minimizes costs. The PMS can also compare data
over long periods.

Summary: The Sabeco brewery group is extremely satis-

fied with the ninth KHS canning line installed at the Binh-
Tay Brewery. The number nine not only brings luck; some-
times you also have to make your own good fortune!

Contact

Werner Gessner Phone: +65 (656) 09313

KHS Asia Pte Ltd, Singapore Email: werner.gessner@khs.com

Tung Minh Tuan Phone: +84 (8) 3820-7746

KHS Vietnam, Email: tung-minh.tuan@khs.com
Ho Chi Minh City
Innovation

Innovation  Page 3247

Innovations
that will make you more competitive

The development engineers and practice-oriented customer advisors at KHS

really know what customers want / The motto is: if innovations have a
chance at KHS, then the customer must measurably profit from them, in terms
of availability, product quality, environmental friendliness, and cost,
for instance. One thing is clear: we want to create added value that gives our
customers a real competitive edge.
competence 02.2012 32/33

34 Little big machine: the new Innofill Glass Micro

has been specially developed for small breweries and soft drinks bottlers
provides high-performance technology
is hygienic, simple, flexible, durable, compact, and robust.

38 The best system for the best vintages: the Innofill Glass, now
for the wine, sparkling wine, and spirits sectors
in three custom-made versions
satisfies the highest hygienic demands.

42 Better Basic: the Innopack Kisters Basic series

optimizes packaging qualities in the low capacity range
processes all kinds of containers and packs for all sectors
is a reliable and robust technical system.

46 Specifically for fruit juices: the Innosept Asbofill ABF for 28-mm necks
is perfect for the fruit juice sector
can be easily converted to 38 mm (and vice versa)
has all the advantages of aseptic cold filling.

A QR code (left) is provided for each article in the Innovation section.

You can use a smartphone to send an email to the person who
can provide more information. Simply download an application (app)
which allows you to scan in the code with the smartphone camera.
Some free apps are listed below:

iPhone AppStore RedLaser

Android Market Barcode Scanner
Blackberry App World BeeTagg
Innovation

Little
BIG
MACHINE
competence 02.2012
A newly developed filler for smaller companies with the technology
of high-performance machines
/
KHS presents the Innofill Glass Micro hygienic, simple, flexible,
durable, compact, and robust. Its just what medium-sized breweries and
soft drinks bottlers need.
M edium-sized companies can now make use of the
Innofill Glass Micro that can fill beer and soft drinks
into glass, aluminum, and even plastic bottles. How could
we describe the Innofill Glass Micro in one sentence? Per-
haps as a high-quality, hygienically designed filler thats
easy to operate and service, is extremely flexible, compact,
The Innofill Glass Micro for a
whole range of products and
containers
and robust with a long service life, and is also economical
and environmentally friendly to boot. In other words, just
what breweries and soft drinks bottlers want for their bot-
tling lines. The following article provides further informa-
tion on the new Innofill Glass Micro, listing a dozen chief
components and plus points.
Plus no. 1: extra-transparent machine housing
The glass or Makrolon housing provides plenty of access
for cleaning and maintenance. It also ensures that the fill-
ing process can be viewed from all sides. The sloped, stain-
less steel front table transports product residue, foam, and
water away from the critical hygienic areas of the filler.
34/35
In addition, there are large distances between the sloped
table plate and the open bottles; fewer, sloped surfaces
minimize the risk of contamination; lack of crevices pre-
vents unwanted biofilm from forming. The front table is
also clearly visible from below and easy to clean, and there
is ample floor clearance.
Plus no. 2: hygienic bottle conveying
Bottles are transported by a stainless steel conveyor with
side openings. This makes manual cleaning a simple af-
fair. An optional automatic sanitizing system with spray
nozzles for critical areas is available. The feed screw drive
is located underneath the table plate and well protected.
Plus no. 3: servo technology in use
Highly dynamic servo drives in the carousel, rinser, and
front table area comply with the latest energy efficiency
categories and thus reduce day-to-day operating costs.
Joint shafts and angular gearboxes with low levels of effi-
ciency are now a thing of the past. The result? An efficient
use of energy and low operating and maintenance costs.
Innovation
Spotlight: what the
Innofill Glass Micro can do
The new Innofill Glass Micro filler series from KHS has been specially devel-
oped to meet the requirements of medium-sized breweries and soft drinks
bottlers. Its specifications are as follows:
Bottles Glass or aluminum bottles;
plastic bottles optional
Bottle sizes 0.1 to 3.0 liters
Capacity 6,000 to 25,000 bottles per hour
Size 24 to 60 filling stations
Pitches 94, 113, and 141 millimeters
Beer filling temperatures 4C to 16C
Soft drinks filling temperatures Up to 20C
Filler monoblocking With one or two cappers
Optional: with a single-channel rinser
(one-way bottles)
Machine installation/ Very short installation time thanks to the
commissioning modular/open construction and very few
functional units
Plus no. 4: low-oxygen filling process
The filling system is equipped with aseptic seals, mem-
branes, and expansion joints. The advantage of this is that
no deposits and biofilms are formed when product, gas,
and CIP media are fed in. The computer-controlled, sin-
gle-chamber DPG-ZMS pressure filling system is used. This
gives customers consistent filling quality with precise fill
levels, even during stop situations and acceleration phases,
a low-oxygen filling process, and targeted savings in CO
(only 230 to 250 g per hectoliter are used thanks to KHS
double- volume rinsing process).
Plus no. 5: simple changeovers
The operator can easily store and recall filling parameters
for specific combinations of product and bottle on the op-
erator panel using the product type memory. This means
fast changeover; no compromise settings necessary; with
new bottle sizes only the return gas tubes have to be ex-
changed on the filling valve. A quick-change mechanism
on the lighter weight bottle guide parts enables produc-
tion to resume very quickly, and the height of the filler
carousel can be automatically adjusted to different bot-
tle sizes.
Plus no. 6: easily accessible filler carousel
Easy access means that no external control elements or
cams are needed to control the filling valves; this is signif-
icant progress in machine hygiene, giving free access for
cleaning and disinfection.
Plus no. 7: twin-valve control for the first time
The twin-valve control implemented here for the first time
is extremely beneficial. To date a total of three pneumatic
switching functions, three solenoid valves, three pneu-
matic hoses, three electronic outputs, and three sets of
wiring were needed per filling station. In the new process
two filling valves have been combined to make one pro-
cessing unit. Gas processes (evacuation and snifting) are
regulated by gas control valves that are shared by two ad-
jacent filling valves. This results in every second gas cyl-
inder with all its drive elements and wiring to the filling
valve being made redundant. The product valve cylinders
are controlled by a solenoid valve also shared by two ad-
jacent filling stations. This means that about 50% fewer
electropneumatic control units are needed, the quality
competence 02.2012
With twin-valve control the product valve
cylinders are controlled in parallel by a
solenoid valve shared by two filling stations.
remains the same yet the complexity and number of parts
are considerably reduced, operating costs are lower, and
there is much less maintenance effort required.
Plus no. 8: compact valve manifold saves space
The fittings on the compact valve manifold next to the
filler cladding have been constructed vertically. This means
that 50% less space is required than for classic valve mani-
folds, there is improved accessibility to all fittings for main-
tenance and inspection, the media passages between
the valve manifold and filler carousel are kept short, and
cleaning processes are quick.
Plus no. 9: simple CIP sanitizing
Rinsing valves locked into place by seat bolts beneath the
filling valve seal these filling valves during CIP sanitizing.
The advantages of CIP sanitizing are that all passages and
the hygienically critical inside of the centering bells can
be reliably cleaned. CIP sanitizing is also possible when
the filler is stopped; this process can be fully automated
if required. This makes filling valves easily accessible, with
smooth surfaces for optimum exterior cleaning.
Plus no. 10: low maintenance
The rotary leadthrough that feeds beverage and process
gases into the filler carousel is equipped with greaseless
sealing systems. The sealing surfaces are ceramic coated.
This means that they have a long service life and do not
36/37
come into contact with lubricants. Collector ring distrib-
utors with proven gold/gold technology ensure a low
dynamic noise and constant contact quality. Customers
thus profit from a very long, maintenance-free period of
operation.
Plus no. 11: the crown corker
The crowning elements on the KHS crown corker, tried-
and-tested in the high-performance range, have spacious
openings for sanitizing. Like the cork chute and sorter they
are included in the automatic cleaning cycle. The result is
a robust construction with few components and ensured
hygienic safety.
Plus no. 12: components from high-performance
filling technology used
As a specialist for high-performance filling technology
KHS has incorporated many elements in the Innofill Glass
Micro that our engineers also use in our high-performance
fillers. These include filling valves, lifting elements, crown-
er and capper elements, closure sorters, and rinsing sta-
tions and processes, for example. The technological pa-
rameters used in the high-performance range thus also
apply to the Innofill Glass Micro. This opens up a number
of new benefits to medium-sized companies in the bev-
erage sector and helps to boost their competiveness. As
promised.
Contact
Ludwig Clsserath Phone: +49 (671) 852-2501
KHS GmbH, Bad Kreuznach, Email: ludwig.cluesserath@khs.com
Germany
Michael Beisel Phone: +49 (671) 852-2205
KHS GmbH, Bad Kreuznach, Email: michael.beisel@khs.com
Germany
Kecheng Ding Phone: +1 (262) 787-3291
KHS USA, Inc., Waukesha, USA Email: kecheng.ding@khs.com
Innovation

Spotlight: which machines fill what

Filling process
DNRT NDRT NRT

Wine
Non-alcoholic wine
Slightly carbonated wine
Carbonated mixed wine beverages
Sparkling wine and cider
Alcohol-free sparkling wine
Spirits
Carbonated products
(up to 11 g/l) (up to 3.5 g/l)
Still products
(water, juice beverages)
competence 02.2012 38/39

The best system for

the best vintages
The wine, sparkling wine, and spirits sector can now also profit from
the new KHS Innofill Glass filler
/
Companies can select the most suitable version according to their
product portfolio to meet all hygienic and technological requirements,
however demanding.

Promises
must be kept. But every now and then this takes time
and a certain boldness. KHS competence heralded the
start of a new era at the end of 2011 when KHS intro-
duced the next generation of fillers for glass bottles with
its Innofill Glass filler platform, again acting as a bench-
mark (see articles in the 2/2011 issue of the magazine or
at www.khs.com/glass). And this innovative platform has
so many benefits that the companies who use it cannot
fail to gain the edge over their competitors. Innofill Glass
gives them high-performance technology for large filling
quantities, where consistent hygienic design and automa-
tion have been given top priority in all stages of design
and construction. And KHS promised that other filling sys-
tems based on this revolutionary high-tech filler concept
would follow, also and especially for smaller volumes, for
other types of bottle, and for other products, such as wa-
ter and wine.
Voil! Just under a year later customers can take KHS
at their word. The wine, sparkling wine, and spirits industry
can now also profit from the above benefits, choosing one
of three models of the Innofill Glass. The first is the Innofill
Glass DNRT filling system for the entire range of products
sold by the wine, sparkling wine, and spirits industry. For
low-oxygen filling there are processes with single or mul-
tiple pre-evacuation and CO purging: the Innofill Glass
NDRT for still, slightly carbonated products, and the Inno-
fill Glass NRT for non-carbonated beverages only. All three
variants have the following main features in common:
Hygienic design
Smaller sloped or curved surfaces with no crevices or cor-
ners allow liquid and glass fragments to slide to the floor,
prevent any unwanted biofilm from forming, and reduce
the risk of contamination. External cladding made of glass
or Makrolon panels makes the system transparent and ac-
cessible on all sides; height-adjustable pantograph joints
with aseptic sealing systems enable media to be fed hy-
gienically during beverage and process gas feed processes.
Innovation

Gallo wine bottlers now has

eleven KHS fillers in operation,
one of which is the new
Innofill Glass DNRT system.

A fi r st :
proving successful at Gallo
Gallo Winery in California is continuously growing and recently needed two new filling systems. The specifications
for the supplier were that they had to produce a consistent machine concept, reliable service, compatible compo-
nents, and a low total cost of ownership or TCO. And they did in the form of the Innofill Glass DNRT from KHS.
Eleven KHS fillers, including five DNRT systems, are now in operation at the worlds largest wine bottling plant un-
der family ownership.

Easy cleaning saving up to 98% of water shortens delivery times for

The belt drive and servo motor for the feed screw are en-
cased in stainless steel, servo drives power the star wheels
and closure systems, and there are no open gear wheels,
gearboxes, or lubrication in the hygiene area: with these
essential elements, cleaning is fast and simple.
Lightweight tubular ring bowl
As opposed to the classic rectangular ring bowl the tubu-
lar design cuts down on the consumption of cleaning me-
dia and water. Shorter heating and cooling periods and
lower drive forces also help to save energy.
Faster operation
All format parts (which can be adjustable on request) can
be changed without the need for tools, and the filling
valves secured and released using just two cap nuts; the
beverage and media feeds and pneumatic supply connec-
tions are automatic. A space-saving, compact valve mani-
fold attached to the filler cladding makes all fittings easier
to access for maintenance and inspection.
spare parts and simplifies maintenance.
Optional rinsing cap system
An automatic rinsing cap system can be integrated into
all three filling systems. During filling the rinsing caps are
hidden behind metal jackets and therefore well protected
from glass fragments and product residue; they are only
positioned under the filling valves when the sanitizing
process begins, with the rinsing pressure sealing the caps.
This is particularly important when filling is to be carried
out under ultraclean conditions, such as for sensitive prod-
ucts like non-alcoholic wine with cold sterilants, alcohol-
free, carbonated mixed wine beverages, or non-alcoholic
sparkling wine. For this purpose all three filling systems
can be monoblocked with a single-channel or two-chan-
nel rinser that is precisely tailored to requirements. All ver-
sions can process between 10,000 and 72,000 bottles per
hour holding from 0.1 to 3 liters. As the setup can also run
without a vacuum, all three Innofill Glass models are also
suitable for PET bottles.

Vacuum pump modules

Contact
These adapt automatically to the prevailing operating
Ludwig Clsserath Phone: +49 (671) 852-2501
conditions and considerably reduce the amount of wa-
KHS GmbH, Bad Kreuznach, Email: ludwig.cluesserath@khs.com
ter and electricity used. The standardized pump version Germany
which can be supplied with ECO cooling on request,
competence 02.2012 40/41

Innofill Glass:
packed with innovations

1
The all-rounder: the Innofill Glass DNRT

The Innofill Glass DNRT, with its operator-friendly prompting from the award-winning KHS interface with an integrated
RFID system, fills everything: wines, sparkling wines, and spirits, including non-alcoholic wine and sparkling wine, slightly
carbonated wine, and mixed wine beverages. The latest chief improvements are warm filling for sparkling wine with a
high CO content, the Trinox system, and the especially gentle, hygienic filling process that takes place under ultraclean
conditions using a swirl fan gas lock. Inside each filling station a special rinsable and sterilizable sanitary room automat-
ically protects the Trinox tube adjustment area which can be freely set to the correct fill level without involving replace-
ment parts. Trinox technology provides accurate fill levels with standard deviations of one millimeter or less, forces excess
product back into the ring bowl using positive pressure, and also ensures that there is an optimum distance between the
beverage and the natural cork. In addition, up to three closure systems can be directly monoblocked with the filler or ret-
rofitted at a later date. A swirl fan gas lock allows product to flow down the inside bottle walls for a low-foam, hygienic fill-
ing process; there are no spray elements that are susceptible to wear protruding into the bottle, the usual changeover of
the return gas tube is no longer necessary, and the gas lock, together with the Trinox process, ensures that the overfill re-
turned to the ring bowl is kept to a minimum. Single or multiple pre-evacuation with CO purging minimizes oxygen pickup.

2
Also for carbonated wine beverages: the Innofill Glass NDRT

Like the Innofill Glass NRT this filling system is a new process derived from the DNRT. Both further developments are spe-
cifically aimed at producers of wine and spirits who dont require classic pressure filling and bottle still or slightly carbon-
ated beverages, such as lightly carbonated wines, at filling pressures of up to 1.5 bar. NDRT is thus the ideal filling system
for retaining the natural carbon dioxide content in wine. The Trinox process also provides head space purging with CO for
products that are sensitive to oxygen.

3
For still products: the Innofill Glass NRT

This system works with balanced pressure filling for still products only. The advantage of this is that there is no loss of fla-
vor or alcohol common to vacuum filling systems, and no outside air is sucked into the system through the filling valves.
Innovation

B ette r
Basic
Optimized packaging quality in the low-capacity range /
The Innopack Kisters Basic series has been providing a robust and reliable
technological service for many years now. Despite this,
KHS is continuously working on improving it with great success.

B asic by name but far from basic by nature: the Basic

series of KHS packers is such a high performer that
it can cope with the most demanding specifications. This
The result is easier machine handling, increased flexibility,
reduced energy consumption, and lower costs and
therefore higher machine availability.
low-speed machine includes shrink, tray, and pad shrink This all means that once again KHS is setting the
packers. It can process all kinds of products common to the standard when it comes to customer orientation. For re-
beverage, food, and non-food industries, packing them quirements that exceed the scope of the Basic concept,
into glass, metal, and/or plastic containers at a rate of 30 the Advanced series is available; this runs at 50 cycles min-
to 70 cycles per minute. Individual containers may range imum per minute, and can be increased to up to 135 cycles
in diameter from 55 to 110 mm, and in height from 110 a minute.
to 350 mm; for product group formations, lengths of be-
tween 110 and 270 mm and widths from 200 to 540 mm
are possible.
Contact
Christopher Stuhlmann Phone: +49 (2821) 503-283
KHS is setting standards KHS GmbH, Kleve, Email: christopher.stuhlmann@khs.com
Germany
The engineers at KHS are continuously working on im-
proving their filling and packaging machinery for the ben- Karl-Heinz Klumpe Phone: +49 (2821) 503-212
KHS GmbH, Kleve, Email: karl-heinz.klumpe@khs.com
efit of their customers. In the Innopack Kisters Basic series Germany
this has resulted in a whole host of optimized features.
competence 02.2012 42/43

1
Single-action levers are just one
of the many improvements
to the Innopack Kisters Basic
Innovation
The main improvements
to the Innopack Kisters Basic
1 4
1 5
 Product feed changeover times reduced
Here, single-action levers replace the previous clamping levers, allow-
ing short conversion with frequent format changeovers on lines with
three lanes maximum. The principle here is simple; when a conversion
is made, the lever is simply turned to the new position and allowed to
lock into place. Done!
2 In the optimized heating chamber more effective ventilators are used,
 Less noise on the guide rails
Optional anti-drumming plates for the guide rails specifically reduce
the noise in the container infeed area, especially with glass containers.
3
 Servo motors make for an easier setup
All functional units now have identical, coupled servo motors with in-
tegrated servo controllers that are controlled by a master control in
the switch cabinet. This reduces spare part stockkeeping and drasti
cally cuts down the amount of cabling needed between the control
cabinets and machines.
 Film cutter has servo drives
for perfect results
A new film cutting and feed system now processes much thinner films
of up to just 25 m in thickness and 880 mm in width with perfect
results. An improved vacuum system that has belts with an even finer
hole pattern also automatically dissipates any electrostatic charge; in
conjunction with an additional antistatic system, this provides maxi-
mum processing reliability. The film cutter is now also servo driven in-
stead of being powered by the main motor and a coupling. This makes
film cutting even more accurate and means there is less wear on the
cutters.
 Blanks handled with less air at less cost
Another option is to have blanks removed from the dispenser by a vac-
uum pump instead of a Venturi nozzle. This cuts down on the amount
of compressed air needed and thus reduces energy costs.
6
 Shrink tunnel saves on energy
improving the flow principle and permitting energy savings of up to
15%. Moreover, maintenance is less frequent and the number of spare
parts required is reduced. Variable hot air nozzles can be perfectly ad-
justed to suit the type of packaging being processed. A new, optional,
energy-saving package sinks energy consumption by up to 20%. This
features a roller shutter system at the infeed and discharge which clos-
es during downtimes and thus prevents thermal energy from escaping.
New insulating elements on the shrink hood prevent any unwanted
loss of heat; thermal energy remains inside the tunnel hood.
Last but not least an optional, automatic sanitizing system for the
conveyor chains makes manual cleaning in the shrink tunnel superflu-
ous. This system consists of a counter-moving, stainless steel brush lo-
cated underneath the chain which removes film debris and particles of
dirt and sweeps these into a drawer. Depending on the local electricity
competence 02.2012 44/45

8
More flexibility for packaging changeover
The revamped Innopack Kisters Basic has more possible variations.
Where packaging options frequently change the shrink packer can
4
now be turned into a tray or pad shrink packer in a process not possi-
ble until now, for example. Likewise, additional modules can also be
integrated, such as a leaflet inserter or film perforator.

9
 Control improved: one operating concept
for two series of machines
As the Basic and Advanced series now have identical control systems
and operator panels, machines from the various series can be easily
operated.

10
 Service with direct online support
Customers can now make use of the Remote Diagnostic Service (ReDiS)
if need be. ReDiS contacts the KHS ReDiS Service Center through a con-
nection in the machine control system; in the best case the fault can
be remedied through remote analysis and online access to electronic
system components. If the problem involves mechanical components,
a KHS specialist can give the service engineer at the machine custom-
ized support and precise instructions.

rates, the gas heater in the optional Eco shrink tunnel can cut energy
costs by up to 50% compared to the electric heating system. At the
same time CO emissions are reduced by up to 60% and no chimney
is needed. The shrink tunnel can also be converted to gas after it has
been installed.
9

7
 Operation much more transparent
The cubic design of the machine body makes the system more opera-
tor-friendly on many counts. Access is easier, and in the packaging area
large, see-through doors allow operators to view the interior workings
of the machine even during production.
Innovation

Specifically
for fruit juices
Theres now an interesting innovation for the new generation of
aseptic linear fillers from KHS / 28-mm neck option for plastic bottle
processing on the successful Innosept Asbofill ABF.

T he principle is as follows: Innosept Asbofill ABF tech-

nology manages the aseptic cold filling of non-car-
bonated, non-alcoholic beverages using the dry steri-
lization method. The two great advantages of this are
maximum aseptic safety and an extremely small sterile
area. While the Innosept Asbofill ABF 711 has sterile zones
of just 1.5 m, a sterile room of only 0.9 m is required for
the Innosept Asbofill ABF 611 (the classic ACF wet process
takes up 65 m of space).
It thus comes as no surprise to learn that this new gen-
eration of aseptic linear fillers is proving successful. Com-
panies can select one or more of the following versions:
The Innosept Asbofill ABF 611 with a capacity of
12,000 0.1 to 0.75-liter bottles per hour, or and coffee and of course for fruit juices and fruit juice
The Innosept Asbofill ABF 711 with a capacity of beverages.
12,000 0.25 to 2.0-liter bottles per hour. The customer decides which version is preferred. If
Extra alternative: whats known as the twin concept the company later wishes to change from the 28-mm neck
which doubles the machine capacity. to the 38-mm neck or vice versa KHS can quickly con-
To date, only bottles with a neck diameter of 38 mm could vert the machine, providing extra security. This also applies
be processed on Innosept Asbofill ABF machines. With the to new-generation Innosept Asbofill ABF machines that
new generation KHS now makes it possible to also pro- have already been installed.
cess 28-mm neck diameters, thus meeting the demands The following outlines the chief technical features,
of many of its customers. In the fruit juice sector in par- options, and benefits of the new technology in addition
ticular bottles with necks measuring 28 mm in diameter to the extremely small sterile zone. All details can be found
are an important option, especially in Asia. Discounters in edition 2/2011 of KHS competence or at www.khs.com/
throughout the world are also increasingly favoring this aseptic).
size of neck for their fruit juices. A factor which is of decisive importance for maximum
The 38-mm neck is primarily suitable for milk and yo- aseptic safety is that bottles are conveyed through the ma-
ghurt beverages, sports drinks, near water beverages, tea chine in just one holder. This eliminates any aseptic risks
competence 02.2012 46/47

28
mm
The new generation of Innosept
Asbofill ABF machines can now
also process plastic bottles with
28-mm necks.

which can occur with conventional switching from one
carousel to another on rotary machines.
Another option is to place a drop of liquid nitrogen in the
head space of the filled plastic bottles to provide extra sta-
bility for the bottle material. Examples of other options,
which are available for the latest generation of Innosept
Asbofill ABF machines and which can be retrofitted if re-
quired, are integration of pulp nozzles into the filling
valves, nitrogen flushing before the filling process, double
filter instead of single filter units in the valve manifolds,
and coding within the production process.
After the bottles have been sterilized with HO they
are transferred to the filling station, which is separated
from the sterilization process by a partition. The filling pro-
cess, which is based on the theory of volumetric filling, is
carried out without contact by two-stage, free-flow fill-
ing valves. The process is safely concluded for all neck ver-
sions by the application of screw caps under aseptic con-
ditions; sports caps can also be processed here if needed.
If required, bottles with 38-mm necks can be closed with a
seal in place of the screw cap. These caps or seals are also
sterilized with HO.
Coming soon
In the near future KHS wants to equip its machines with
units for both 28 and 38-mm necks and with short
changeovers. An appropriate conversion option will be
provided for new-generation Innosept Asbofill ABF ma-
chines already on the market. Also planned is the devel-
opment of an Innosept Asbofill ESL (Extended Shelf Life)
version for still, non-alcoholic beverages in plastic bottles
which are sold through the cold chain. There are thus even
more interesting innovations in store for many companies.
Contact
Stefan Muhs Phone: +49 (671) 852-2897
KHS GmbH, Bad Kreuznach, Email: stefan.muhs@khs.com
Germany
Market report

Market Report
Customer projects and KHS acceptance tests around the globe
competence 02.2012
Spendrups Bryggeri, Sweden
Absolutely
delighted
S pendrups, the renowned family-owned
company founded in 1897, is Swedens
second largest brewery and one of the coun-
trys key producers of beer, soft drinks, and
bottled water. In addition to several major lo-
cal brands, such as Spendrups Bryggeri, Norr-
lands Guld, Mariestads, and Loka, Spendrups
also produces Heineken beer and Schweppes
for the Swedish market. And the company
continues to prosper. Spendrups has now
commissioned KHS to install three systems all
at once: a complete bottling system, a shrink
packer for an existing canning line (both at
the Grngesberg site), and a new packaging
area (in Hllefors).
The bottling line, part of the reloca-
tion of production from Varby to Grnges-
berg, bottles both non-refillable glass bottles
(45,000 0.33-liter and 33,000 0.5-liter bottles
per hour) and non-refillable PET bottles. In ad-
dition to beer, the line is able to process mixed
beverages not just classic soft drinks but also
cider. The line is used to fill a very wide va-
riety of different glass and PET bottle types
and therefore has a very high level of auto-
mation for optimum and fast software-sup-
ported changeover processes with a custom-
ized product-changing concept. The result is a
high degree of utilization and stable produc-
tion. Incidentally, the KHS system came out on
top as the most economical in terms of con-
sumption (e.g. water and CO consumption
and spare part requirements) before the con-
tract was awarded.
The KHS Kisters SP shrink packer pro-
cesses 90,000 0.33-liter cans per hour in an
existing canning line. Spendrups relies on
the new FullyEnclosed FilmPack system. An
Innopack CSM handle applicator applies car-
rying handles to packs. The product type can
be changed quickly at any time. The experts
from Spendrups were sustainably convinced
by the energy and material savings, machine
availability, and the recycling solution.
In cooperation with turnkey contrac-
tor Bavaria Getrnkemaschinen, KHS deliv-
ered the packaging area ranging from the
infeed to the packing machine up to the pal-
letizer for the filling line already in operation.
The heart is a KHS Kisters TSP packaging ma-
chine that runs at a capacity of 36,000 0.5-
liter PET bottles per hour. The machine oper-
ates with a new two-lane, inline film printing
system. With this packer, the focus was also on
high speed, fast changeover capabilities, con-
vincing efficiency, and noticeable energy sav-
ings in addition to reduced costs. An Innopack
CSM handle applicator and a palletizer for
packs and displays complement the packag-
ing area.
The experts from Spendrups Bryggeri
were absolutely delighted with the results of
all projects. The Swedish story of Spendrups
success can continue.
www.spendrups.se
JSC Georgian Beer Company
Three at once
W hat does a company do that only
started up production in April 2012,
makes beer and CSDs, processes a whole range
of diverse containers, has very little space yet
makes the highest demands of the technol-
ogy and efficiency of the supplier? It opts for
KHS! JSC Georgian Beer Company, Brewery
Zedazeni in Saguramo, has purchased no less
that three KHS systems and will soon be oper-
ating at the highest level of production with
its new PET, glass, and canning lines, some of
which are to run in combined operation.
48/49
The PET line outputs 22,000 bottles per hour
on an InnoPET BloFill monoblock, compris-
ing an InnoPET Blomax Series IV stretch blow
molder, and an Innofill DRV filler for five types
of bottle. Still and highly carbonated bever-
ages and beer are bottled. Thanks to the op-
timized layout of the PET line a one-way
glass line for CSDs and beer with a capacity
of 24,000 bph could also be installed in the
existing production shop. Features include
a two-stage rinsing process that meets the
maximum demands for hygiene, a rinser/fill-
er/capper triblock with two capping systems,
a KHS Innopack Kisters TSP (tray shrink pack-
er), and a KHS Innoket 360 S labeler. The en-
tire setup ensures that the bottles and packs
are perfectly processed at the highest level.
A canning line with a volumetric KHS Innofill
DVD filler is connected to the glass line, saving
precious space.
The management at JSC Georgian Beer
Company was convinced by the flexibility of
the new KHS lines, their high level of effi
ciency despite processing many different
product styles and bottle types, and the high
technological specifications regarding hy-
giene and bottle design, all coupled with a
low consumption of energy and process ma-
terials. JSC Georgian Beer Company can now
continue to take the market by storm!
www.zedazeni.ge
Just launched to
the market: plenty
of new innovations
from Zedazeni.
Market report
Brouwerij Haacht, Belgium
Finest filters
B rouwerij Haacht, the third largest brew-
er in Belgium active in its native country,
France, and the Netherlands, has taken deliv-
ery of two new filter systems from KHS, with
which it intends to
improve its filtration results,
cut down on beer loss, and
reduce its energy consumption.
Bearing the brewerys complex production
program in mind, KHS has provided the fol-
lowing setups:
an Innopro Cosmos filter system for spe-
cialty beers with a capacity of 150 hec-
toliters per hour (this minimizes beer
loss), and
an Innopro Getra Eco filter system for
pilsner with an output of 500 hectoliters
an hour (this drastically reduces energy
consumption and maintenance costs
while yielding top-quality results).
KHS worked on the ideal engineering concept
together with the technical team at Brouwerij
Haacht, using 3D planning in the implemen-
tation of part of the project.
www.haacht.com
Imlek Regional Dairy, Serbia
Three firsts
I mlek, the largest dairy in Serbia with a 50%
share of the market, has three firsts to re-
port: its the first dairy in the country to use an
aseptic PET line and the first company in the
Salford Group to do so, and is using KHS tech-
nology for the first time. Imlek bottles milk
and mixed milk beverages and is now to re-
ceive an aseptic PET line for this purpose with
a capacity of 12,000 1.5, 1.0, and 0.2-liter bot-
tles per hour. This consists of a CIP system, KHS
Asbofill ABF 711 C filler, KHS Innocheck fill
level inspector, KHS Innopack Kisters SP 050
Basic shrink packer, and KHS Innoline bottle
JW Lees, Great Britain
KHS enjoys
good
reputation
I t was the good reputation of KHS keg tech-
nology in Great Britain that encouraged
the management of the traditional JW Lees
brewery to order a new keg line from KHS.
The company is to receive a Transomat 1.3
Duo-XL keg washer and racker with a capac-
ity of 144 50-liter kegs per hour. The line is
able to process kegs holding between 30 and
100 liters, has a higher productivity than the
previous line, and uses significantly less en
ergy. The family business, established in 1828
in Middleton in whats now Greater Manches-
ter, invested in a KHS flash pasteurizer in 2011
which is running successfully.
www.jwlees.co.uk
conveyors. The chief benefits for the dairy are
improved product and safer bottling qual-
ity. Imlek belongs to the Salford Investment
Fund, a company in Great Britain that is suc-
cessfully introducing milk and milk products
to market. Salford has three other dairies in
the Balkans: one in Subotica (Serbia), one in
Kozarska Dubica (Bosnia and Herzegovina),
and one in Bitola (Macedonia).
www.imlek.rs
Lakefront Brewery, USA
Innofill Glass
Micro
L akefront Brewery, a successful craft brew-
er based in Milwaukee, Wisconsin, contin-
ues to grow thanks to the excellent quality of
its beer. The previous system was no longer
able to meet the brewerys higher production
requirements. A KHS Innofill Glass Micro filler
is now destined to go into operation, espe-
cially developed by KHS for breweries of this
kind based on high-performance technology
(see page 34). The line, produced at KHS USA
plant in Waukesha, Wisconsin, can process up
to 15,600 12-oz bottles per hour. Owner Russ
Klisch, who has known KHS for many years,
is looking forward to the many advantages
his company can again rely on with this new
system.
www.lakefrontbrewery.com
competence 02.2012
Delta Beverages, Zimbabwe
PET for the second time
T here is a company with a long tradition in
Zimbabwe that virtually everyone in the
country has heard of: Delta Beverages. The
companys origins date back to the year 1898
when the brewery was founded. Nowadays,
the company group bottles Coca-Cola prod-
ucts in addition to beer. Based on Delta Bever-
ages outstanding experience with a KHS PET
line that was put into operation at its plant in
Harare in 2010, the management once again
decided in favor of KHS as the supplier of
another PET line for its Bon Accord bottling
plant in Bulawayo.
Maximum flexibility
The scope of delivery ranges from a blender
system, a blow molder/filler monoblock, to
a roll-fed labeler and shrink packer, up to a
palletizer. The line fills at a capacity of 12,000
2.0-liter bottles per hour and is used to bottle
the entire range of Coca-Cola products, along
with 2.0, 0.5, and 1.0-liter bottles. The special
features include a blow molder that operates
Delta Beverages: a traditional brewery in Zimbabwe.
with UV radiation and preform ionization in
the preform feed. The monoblocked filler is
equipped with a fully automatic valve mani-
fold, UV closure treatment, an automatic CIP
cap feed, and a Class 10,000 sanitary room.
Similar to the filler, the compact mixer is de-
signed for automated CIP and beverage pro-
duction, and is suitable for shipment in a
container. Although the KHS Kisters shrink
packer and KHS palletizer currently process
6 and 12-bottle, shrink-wrapped packs, they
are able to handle other future pack forma-
tions as well.
KHS has been working closely with Delta
Beverages for more than 30 years. The fact
that Delta also relies repeatedly on the ex-
pertise of local, experienced KHS service en-
gineers for line audits and overhauls indicates
the amount of trust that exists between the
two companies.
www.delta.co.zw
50/51
Coca-Cola Canners of South Africa
Loyal partners
K HS has enjoyed a loyal partnership with
Coca-Cola Canners of South Africa for
more than 15 years. A whole range of KHS
systems and solutions has been implement-
ed in the company and working reliably
since their installation. From time immemo-
rial the canning specialists golden rule for
Coca-Cola in South Africa has been to rely
on a supplier with excellent technology and
Maximum productivity,
easy to operate and
maintain, and flexible
service.
forward-looking expertise who avoids inter-
faces, provides flexible, comprehensive ser-
vice, stocks spare parts locally, familiarizes
and trains staff in an uncomplicated manner,
writes all programs for the lines using a com-
mon structure, installs machines and finds
faults quickly, and who can also be relied
upon to make service engineers available at
all times who know the company as well as its
own staff. In short, KHS is in demand.
Hot on the heels of a hot fill PET line (see
article in KHS competence 1/2011), the com-
pany has now ordered various components
for its Wadeville site in order to bring an
older canning line with an output of 90,000
0.33-liter cph for CSDs, non-perishable fruit
juices, and mixed beverages, up to date.
www.coca-cola.co.za
Service

Best value: new from old

Filler upgrades
to order
The central question when companies modernize is Do I invest in new
machinery, or do I upgrade? / In issue 1.2012 of KHS competence we talked
about upgrades for packaging machines. The following article outlines how
beverage companies can profit from filler conversions. The targets are higher
efficiency, more sustainability, and better product quality.

O f course KHS likes to sell new filling and packaging

machines and complete lines! Yet in several hundred
cases a year KHS advises its clients to upgrade its existing
that have been continuously developed over many decades.
Many of these fillers are also quite elderly; thanks to robust
KHS construction and long service lives, its not unusual for
equipment rather than buy anew. Its often well worth these machines to clock up three decades or more. The fol-
companies continuing to trust in tried-and-tested engi- lowing typical and practical examples list various company
neering from KHS and upgrading their filling technology targets, providing information on the project consultancy,
so that its state of the art usually with a fairly modest handling, and implementation offered by KHS, and show-
strain on company technology, time, and budget. ing what kind of results customers can expect.
Such undertakings are triggered by the market. Suc-
cessful bottling plants have to keep up with consumer de-
mands and the pressure of competition and thus constantly Contact
Lothar Wilhelm Phone: +49 (671) 852-2372
search for new solutions, such as better quality products,
KHS GmbH, Bad Kreuznach, Email: lothar.wilhelm@khs.com
higher line efficiency, more environmental friendliness, or Germany
increased ease of operation. The motives and reasons for
Armin Wille Phone: +49 (231) 569-10284
upgrading are many and varied. This is why KHS provides KHS GmbH, Dortmund, Email: armin.wille@khs.com
over 100 different conversions for filling machines. After all, Germany

there are around 4,000 KHS fillers in operation the world Michael Beier Phone: +49 (231) 569-1298
KHS GmbH, Dortmund, Email: michael.beier@khs.com
over, with 120 being added to this number each and every
Germany
year; these operate on over 30 different KHS filling systems
competence 02.2012 52/53

In focus: service by KHS

KHS provides all manner of advice before a decision is made
to upgrade a filler or not, including:

Supplying the customer with detailed information on all the benefits and/
or tasks connected with the upgrade
Giving advice on all measures necessary
Calculating all increases in efficiency
Stipulating improvements in quality
Explaining more environmentally-friendly filling processes
Telling clients which upgrades are feasible and worthwhile
for the filling system in question
Making recommendations, and
Providing evidence of the benefits these would entail.

Once the upgrade has been specified,

There is usually an on-site meeting at the bottling plant

KHS Service assesses the existing filler and peripheral machines
The experts stipulate which parts are necessary for the intended filler upgrade
KHS manufactures the required parts in the same top quality as for new machines
KHS tests parts and/or assemblies at the KHS factory, and
Only delivers these to the beverage plant after testing
This includes installation, consultancy, and after-sales service
Everything is closely coordinated with the customers personnel, to whom the
KHS experts pass on their expertise.
Service
Customer target:
to introduce new bottle types
The situation: filler upgrades are ever more
important to the beverage sector and are top
of customer wish lists. Clients want to be able
to perfectly adapt their range of products and
bottles to suit new consumer demands.
KHS solution: both in theory and on its own
test bays KHS first checks how filling process-
es can be best configured using the requested
(or feasible) bottle designs. This provides in-
formation as to which additional equipment
the plant needs for the best individual filling
procedure. If new plastic bottles are required,
KHS often goes on to provide advice on the
development of the bottle shape, including
suggested designs and packaging options.
Computers simulate the contours of the con-
tainer; prototypes have to prove themselves
on KHS lab machines.
The experts at KHS then make sure that these
new glass and plastic bottles can be processed
on the designated filler with their given di-
mensions, and that there are no installations
on the filler that could hinder conversion. Ei-
ther information on the filling system is con-
tained in CAD documents or especially with
older machines the relevant data must be
recorded in situ. Once everything has been
clarified, KHS manufactures new, precision
format parts as for new machines, applying
top standards of quality and identical criteria.
Customer benefits: filling technology that
is specifically tailored to the bottling plant,
a larger product portfolio, a more successful
market presence, and a lower cost of invest-
ment than for the purchase of a new machine.
Customer target:
to improve the filling process
The situation: many bottling plants want the
complete filler turret replaced to achieve a
better filling process.
KHS solution: in cases like these KHS re-
news all filling elements and their peripher-
als, bringing them into line with the latest
technology. In this way an outmoded, me-
chanically controlled filling system can be
converted into an electronic filling system.
The new filler turret is tested at the KHS fac-
tory prior to delivery. KHS specialists then en-
sure that this perfectly links in with the over-
all system on site.
Customer benefits: a better quality filling
process, which is faster, especially hygienic,
and gentle to the product.
Customer target:
to increase the product quality
The situation: a filler upgrade could specifi-
cally increase the product quality of beer in
glass bottles.
KHS solution: to integrate the double pre- Control by the neighboring valve at the push of a
button; the filling valve remains fully functional.
evacuation method. During pre-evacuation
the glass bottles are purged twice with CO as
they are pressed against the filling valves. This
is followed by final evacuation. As a result, the product flows into a virtually pure CO atmos-
phere in the bottle.
Customer benefits: the much reduced oxy
gen content in the product improves its
quality.
Customer target:
to further improve oxygen pickup levels
The situation: the market is calling for even
better product quality and even longer shelf
lives.
KHS solution: a foaming unit (HPI device) in-
tegrated into the filling system with propor-
tional pressure control provides optimum
pressure. The principle is as follows: hot wa-
ter is introduced to the product at high pres-
sure, causing the product to foam and thereby
force air out of the neck area before the bot-
tles are capped. The scope of delivery and in-
stallations include a high-pressure pump with
a proportional valve and motor, a heating
tank, an injector arm with integrated temper-
ature monitoring, and the program that con-
An HPI device or foaming unit included in the filling trols high-pressure injection according to the
system improves oxygen pickup values.
speed of the filler.
competence 02.2012 54/55

Customer benefits: obtain best possible
shelf life of the product by minimizing the
oxygen pickup in the bottle. Individual tem-
perature regulation for maximum product
safety. Manual adjustment of the injector arm
is no longer necessary. Stored, product-spe
cific programs can be reproduced at any time.
production. The inductive flow meter (IFM)
can then be replaced at the end of production.
Customer benefits: disruptions in production
can be reduced to a minimum, thus boosting
machine availability.

Customer target:
to achieve higher machine availability
for volumetric filling
The situation: beverage companies upgrad-
ing their fillers often wish for an increase in
machine availability.
KHS solution: a software package for volu-
metric filling systems enables irregularities
at one filling station to be compensated for
by this being controlled by the neighbor-
ing valve. The relevant filling station can be
bridged by pressing a button on the touch
screen; bridging makes sure that the fill-
ing valve remains fully functional during
Customer target:
to achieve higher machine availability
for aseptic filling
The situation: see left.
KHS solution: the experts at KHS have rede-
signed the conveyor system on older rotary
aseptic machines so that external guides are
no longer required and bottle clamps used
instead.
Customer benefits: bottle control is much
more stable, and machine availability thus
increased.
Customer target: Siemens S7 control: electronically controlled filling
to achieve more efficiency systems can be converted to the state of the art.

for PET fillers

The new bottle infeed on PET fillers equipped with
transfer star systems without front tables boosts
efficiency.
The situation: the susceptibility to fault on
PET fillers equipped with transfer star systems
without front tables is to be lessened.
KHS solution: to integrate a new bottle in-
feed. The infeed plate used to date between
the air conveyor and infeed star is replaced
by an extension of the air conveyor. The soft-
ware is then adapted accordingly.
Customer benefits: less susceptibility to fault
and therefore considerably greater efficiency
of the filling system.
Customer target:
to use up-to-the-minute control
technology
The situation: very near the top of the list of
filler upgrades required by KHS customers is
the conversion of electronic filling systems to
up-to-the-minute control technology, such as
from a Siemens S5 to Siemens S7 controller.
Companies want maximum efficiency.
KHS solution: the main tasks here are to
switch over the hardware components, such
as the computer and the input and output
cards, decide which interface is best, and then
update the software. The function of existing
elements such as sensors and drives must also
be checked, and if necessary these must be
replaced.
Customer benefits: an unlimited supply of
spare parts is ensured for the near future. Op-
erational reliability is also improved, as is the
ease of operation; in addition, operators have
access to more information on the filling pro-
cesses than was the case to date.
Customer target:
to improve crown corker technology
The situation: one popular upgrade for older,
mechanically controlled beer fillers is to install
a new turret to the crown cork capper that
utilizes advanced, ultramodern technology.
Service

New crowner turrets for crown cork cappers are hygienic and easy to maintain.
competence 02.2012
In the crown cork feed the crown corks are directly
blown in by sterile air.
KHS solution: the crowning head support,
crowning elements, crown cork feed, sorter,
flushoff facility, torque dampers for the tur-
ret, and all the necessary electrical compo-
nents and format parts are renewed. The new
crowner turret is assembled at the KHS fac
tory and tested on specifically configured test
bays using crown corks provided by the client.
Customer benefits: increased crowning qual-
ity, improved hygiene (microbiological prod-
uct safety), gentle crown cork handling,
longer crowner part service lives, shorter con-
version times during product changeovers,
and easy maintenance.
Customer target:
to achieve greater sustainability
for the rinsing system
The situation: customers can consider this
type of conversion if not all bottles have to
pass through the rinsing system.
KHS solution: to integrate a rinser bypass
with a standard KHS front table. A transfer
star is installed between the infeed and dis-
charge stars which guides the bottles straight
past the rinser to the filler. This demonstrates
how customer demands can be easily and
56/57
efficiently met while taking the aspect of sus-
tainability into full account.
Customer benefits: this makes bottle convey-
ing to the filling system even faster and also
saves on rinse water.
Customer target:
to achieve greater sustainability in
production
The situation: upgrades that result in more
sustainable production have recently moved
into ever sharper focus.
KHS solution: there are many possible con-
versions here. For instance, beer bottlers can
make considerable savings in water if they
use the KHS Eco vacuum pump. Existing vac-
uum pumps can be easily swapped for the
Eco version. In the Eco vacuum pump a mix-
ture of gas and water passes to the sealing
water tank. While the compressed gas is be- Bio format parts made of stainless steel
are extremely durable and easy to clean.
ing discharged, the water passes to a heat ex-
changer where it is cooled. Theres therefore
no need to add fresh water to reduce the wa-
ter temperature.
Customer benefits: as opposed to classic
pump systems the Eco vacuum pump prom-
ises companies water savings of around 95%. Results: these example conversions
for KHS filling systems illustrate
that KHS has the right system
Customer target: whatever type of upgrade is required.
to achieve greater sustainability Whats more, fillers of any type
for format parts and age can be adapted to suit new
The situation: many bottling plants wish to requirements. And dont forget
use new format parts to gain the maximum that with its service locations on all
benefit. continents KHS Service is on site
KHS solution: to use newly designed, stain- fast whatever the situation world-
less steel, bio format parts that are much wide. And thats a promise.
more robust than parts made of plastic and
have a much smaller surface area.
Customer benefits: bio format parts are
lighter and faster to clean, more durable,
considerably reduce the amount of damage
caused by broken glass, and also minimize
maintenance costs thanks to the use of sim-
ple plastic wear strips.
Solutions for sectors
competence 02.2012 58/59

The Japanese Sapporo Group expands into Vietnam / It has now invested
in a new brewery with three KHS turnkey lines for bottles, cans, and kegs.
KHS is the market leader for canning lines in Vietnam, and in the meantime
has installed around 20 canning lines at different companies in the country.

The Innofill DVD can filler,
electronically controlled
and with 30 filling stations,
is the center of the line.
Good Morning
Vietnam
V ietnam is waking up. Its already the third
largest beer market in Asia after China
and Japan, with a young, growing population
of currently 90 million people and optimally
located for exports to neighboring countries.
Could there be better conditions for invest-
ment for a brewery which is on the road to
expansion? Whether the answer is yes or no,
these were reasons enough for Japans Sap-
poro Breweries to found Sapporo Vietnam
Ltd. in 2009 as a joint venture with the state-
owned, Vietnamese company Vinataba (Viet-
nam National Tobacco Corporation).
In doing so, the Japanese were able to
look back on the positive experience they
have had with their first investment out-
side Japan. In 2006 they took over the Slee-
man Brewery in Canada and subsequently
made Sapporo Premium the number one,
premium Asian beer brand in North America
with annual growth rates running into dou-
ble digits.
The prospects for the new subsidiary in South-
east Asia are also extremely promising. Today,
the Vietnamese with an average age of 28
already drink around 25 million hectoliters of
beer per year or 28 liters per head, and the
high growth in the economy and population
Beer consumption is
rapidly increasing
make double-digit annual growth forecasts
appear thoroughly realistic. The annual beer
consumption in Vietnam is expected to reach
almost 70 million hectoliters by 2025.
The prices that can be achieved here are
also attractive. The average cost of 100 liters of
beer in China is currently about 25 and around
50 in India yet in Vietnam approximately 60
are paid. In addition, the country is logistically
Solutions for sectors
well placed for exports to other countries in
Southeast Asia, as the elongated coastal state
borders directly on China, Laos, Cambodia, and
the South China Sea with the Philippines.
Following a test phase with positive re-
sults all round, the company built its own
brewery in Ho Chi Minh City in 2011. At the
same time Sapporo Vietnam invested in three
KHS lines: a canning line, a refillable glass bot-
tle line, and a keg racking line. Both the tech-
nical systems and service quality are impressive
at KHS, says Hirofumi Kishi, general director
of Sapporo Vietnam, justifying his decision.
Sapporo has great hopes, particularly
for the canning line. This is because in Viet-
nam canned beer is a sign of prosperity and
the Western lifestyle. Although 70% of beer is
currently sold in bottles, experts believe that
the combination of premium beer and chic
cans harbors considerable growth prospects
in the country. By 2020 the market share of
premium beer is expected to double to 30%.
Among other things, the marketing depart-
ment also decided on the elegant, symbolic
Spotlight: Sapporo Breweries
Founded 1876, making it the oldest brewery group in Japan
Subsidiary of Sapporo Holdings with
alcoholic beverages (72% share of the turnover
on the national market, 6% on the international
market)
soft drinks and food products (9%)
restaurants (7%), and
real estate (6%).
Market positioning and strategy
Fourth largest brewery in Japan with five breweries and a 12%
market share; expansion into international markets
colors of gold and black for the can design,
as the Vietnamese associate good quality and
wealth with the color gold.
The KHS canning line is currently
equipped for a capacity of 18,000 0.33-liter or
13,000 0.65-liter cans. The line also impress-
es with its gentle filling. The Innopal ASH de-
Canned beer is a sign
of prosperity and
the Western lifestyle
palletizes the cans and raises them to the re-
quired position in a shaft that is enclosed on
three sides. A pusher system enclosed on four
sides controls the centering of every single
layer during depalletizing.
The heart of the line is the electronically
controlled Innofill DVD volumetric filler with
30 filling stations. It allows the system to be
changed over to deal with varying cans of
competence 02.2012
A special feature at Sapporo:
the Innofill DVD fills cans from
the bottom.
the same diameter at the press of a button,
saves time, and thus increases the availability
of the machine.
The refillable glass line outputs 18,000
0.33-liter glass bottles per hour, and is de-
signed to be expanded to 30,000 bottles per
hour in a second development stage. It cur-
rently shares the resource-saving Innopas PI
SC pasteurizer with the canning line, as the
two lines still work alternately.
Apart from this, the glass line also com-
bines gentle filling with high flexibility:
TOP On the Innokeg Till Keg Boy C2 the The Innopack SP single-column modular
washing and racking stations are mounted
packer can be freely programmed and
on a common base frame.
LEFT The can discharge processes optimizes paths and cycle times
18,000 0.33-liter or 13,000 0.65-liter cans
T
 he double-ended version of the
per hour.
Innoclean DM bottle washer spatially
separates clean and dirty bottles; this
is particularly important in the tropics
The Innofill DPG-ZMS filling system
is easy to use and maintain, can be
changed over without any problems,
and enables low-oxygen filling and
therefore the best beer quality.
60/61
For the keg line Sapporo Vietnam opted for
the Innokeg Till Keg Boy C2 semi-automatic
keg washing and racking machine, in which
the washing and racking stations are installed
on a common base frame.
Like the can, Hirofumi Kishi also sees con-
siderable potential for keg containers, which
currently have a market share of only 1%.
One of the reasons for the low demand for
beer in kegs is surely that at the moment only
a few breweries stock this container. We in-
tend to position ourselves as a pioneer with
kegs in Vietnam. The success story continues.
Contact
Werner Gessner | KHS Asia Pte Ltd, Singapore
Phone: +65 (656) 09313
Email: werner.gessner@khs.com
Tung Minh Tuan | KHS Vietnam, Ho Chi Minh City
Phone: +84 (8) 3820-7746
Email: tung-minh.tuan@khs.com
Solutions for sectors

Vietnam could
overtake Japan on
the beer market!
Hirofumi Kishi
General director of Sapporo Vietnam Ltd.
competence 02.2012
Interview with Hirofumi Kishi,
general director of Sapporo Vietnam Ltd.
KHS competence: Sapporo Breweries is continuing to expand first
a new plant in Canada and now in Vietnam. Whats the background
on this?
Kishi: As the first Japanese brewery group to operate its own brewery
in Vietnam, were hoping for considerable success for our Sapporo Pre-
mium brand on the Vietnamese market, not least because of our pio-
neering status.
Vietnam really does have outstanding growth prospects thanks to its
demographic and geographic situation.
In addition to all these advantages there are no cultural barriers be-
tween Japan and Vietnam; therefore nothing stands in the way of
market growth for Sapporo Premium. If beer consumption increases
as forecast, by the end of the decade Vietnam could be Asias second
largest beer market and therefore ahead of Japan.
Sapporo carried out a trial run before the actual launch. What were
the objectives here?
Above all, there were three things we wanted to find out. Firstly,
whether the taste of Sapporo Premium was accepted in Vietnam; sec-
ondly, whether the packaging was right; and thirdly, whether sales
partners were willing to include Sapporo Premium in their range.
And after that there were no half measures.
To ensure that our staff work in line with the Sapporo philosophy from
the very beginning, on the Vietnamese market weve not taken over an
existing business as is often the case but established a completely new
brewing plant. Weve launched the business here with newly appoint-
ed staff whove been trained in the Sapporo philosophy right from the
beginning.
What were the factors in favor of KHS as your partner of choice?
Ultimate product quality and sustainable operating methods are two
particularly important aspects for us. KHS meets our high expectations
in this regard in every respect. By investing exclusively in KHS technol-
ogy at our brewery just outside Ho Chi Minh City, were ensuring high
quality for our Sapporo Premium beer in bottles, cans, and kegs from
the very start.
62/63
What do you see as the next steps?
Were taking on 150 sales representatives whose task will initially be to
establish our premium beer brand in and around Ho Chi Minh City. At
the same time, well be launching advertising campaigns for Sapporo
Premium in 2012 on TV as well as in other areas. Well then continue
to expand our sales area in Vietnam from 2013.
With what objectives?
By 2016 we can easily see Sapporo Premium becoming the most impor-
tant premium beer brand on the Vietnamese market after Heineken.
We hope to achieve sales of 1.5 million hectoliters for Sapporo Premi-
um in 2020 ...
KHS meets our expectations
in every respect
... which will mean a great upheaval on the Vietnamese market. Are
there any further developments?
We also foresee changes concerning the distribution of container types
on the market. In our estimation, cans in particular will become more
and more popular on the Vietnamese market in years to come. Canned
beer is in here, and is also given as a present on various occasions.
But that surely doesnt exhaust Sapporos expansion plans in Asia?
We can easily envisage building new breweries in other Southeast
Asian countries in the future if the demand for Sapporo Premium were
to increase.
Mr. Kishi, thank you very much for this candid interview.
Solutions for sectors

The innovative Innofill Glass filling system

is consistently hygienic in design.
Here, the crown corker area.
competence 02.2012 64/65

Martens Brewery, Belgium, turns technological advance

into a competitive advantage / The company has trusted in
KHS systems for decades, proving itself to be an outstanding
innovator with top standards of quality, also in the B2B
sector. Martens recently invested in two pioneering develop-
ments from KHS:

+ The Innofill Glass filler series, and

+ The Innopro ECOSTAB pilot machine for regenerative
beer stabilization.

The
pioneers
J an Martens likes to make quick decisions.
However, stresses the joint owner and
manager of Martens Brewery in Belgium,
they have to be well founded. Martens first
proved his point at Brau Beviale 2011. He and
his team of experts came to view the exhib-
its at the KHS booth, studying them in detail,
making comparisons and recognizing the
benefits of the new technology. While still at
the show Martens Brewery ordered a modern
filler for glass bottles that has a whole host
of benefits.
Another example of Martens quick de-
cision-making was when KHS experts visited
the brewery in Bocholt in East Flanders and
happened to mention a newly developed set-
up for regenerative beer stabilization which
enabled continuous operation. We listened
very carefully, remembers Jan Martens, and
were quickly convinced that this was just the
kind of system wed been looking for for some
time. He smiles, We didnt hesitate and de-
cided to order the pilot system immediately.
And that was exactly the right thing to do.
Family brewery in its
eighth generation
To understand where Martens gets his en-
trepreneurial energy you have to know a bit
about the history of the family brewery that
is now in its eighth generation and run by Jan
and Fons Martens. Brouwerij Martens, to give
it its proper Belgian name, is a very special
brewery. It was founded in 1758 and since
then the Martens family has demonstrated
an extraordinary pioneering spirit which
seems to run deep in the family, even up to
now. Both on the Belgian and international
beer markets the company has written several
chapters in the history of beer in its role as pio
neer (see Spotlight: the innovators at Martens
Brewery). Says Jan Martens, We watch the
markets as closely as possible and make sure
that we generate competitive advantages for
ourselves by acting fast.
The development of the brewery illus-
trates that the family has consistently applied
this strategy and proved very successful in do-
ing so. In the middle of the 20th century the
microbrewery sold just 30,000 hectoliters of
beer a year. When the eighth generation of
Martens took the helm at the beginning of
Solutions for sectors
In designing new
products and pack-
aging and by using
technical systems
we hope to gain
even more bene-
fits, such as a boost
in efficiency and
even better product
quality.
Jan Martens
Joint owner of Martens Brewery
the 1990s beer sales were already at around
300,000 hectoliters per annum. Since then
sales have mushroomed. In 2003 the figure
stood at 1.5 million hectoliters, and by 2011
this had risen to 3 million.
Martens Brewery has also long been ac-
tive on the international scene and exports
85% of its beer, with over one million hecto-
liters going to Germany alone each year. The
company also supplies many other European
markets and also Israel, the USA, and Australia.
Brouwerij Martens recently branched out
into Asia, acquiring shares in a modern Mar-
tens brewery near Shanghai, among other
projects. The brewerys main areas of pro-
duction are generic brands in the entry-level
price segment (2.8 hectoliters per year) and
contract filling.
Martens success is surely attributable to
the companys great flexibility and courage
to tread new paths. Take Aldi, for example.
Flexibility and courage
to tread new paths
When Germany passed its mandatory deposit
law in 2002, Aldi consequently struck Martens
beer sold in one-way glass bottles and cans
off the list.
The discounter then approached its trust-
ed partner Martens with the following de-
mands: to quickly produce a sophisticated PET
concept for beer of outstanding quality, pro-
viding large quantities with an identical price
structure bottled in PET that is 100% recycl
able. Together with KHS Martens reacted with
its usual dynamism, and just a few months later
was once again supplying Aldi with beer. Inci-
dentally, this partnership entered its 50th year
in 2012.
Martens Brewery has now invested in not
only one but two innovative KHS systems. The
following gives a brief rundown of these new
developments.
The new KHS Innofill Glass DRS-ZMS filling
system is convincing
with its fully optimized hygienic design
with its improved filling quality that util
izes especially gentle, low turbulence fill-
ing and a low oxygen pickup
with its improved line availability thanks to
short cleaning
with its reduced costs for maintenance, en-
ergy, water, and cleaning media.
The KHS Innopro ECOSTAB beer stabilizer is
convincing
with its continuous output 24/7 through the
use of several redundant system components
with three stabilizer modules, each with
three columns
with its output of up to 600 hectoliters per
hour

in that it avoids over-stabilization and
under-stabilization

with its simple, extremely reliable, and
thorough cleaning
with its lower cost of investment compared
to horizontal mesh or gap cartridge filters,
enabling small and medium-sized brewer-
ies to use the new machinery
with its reduced costs for materials in con-
tinuous operation (only 50% of the PVPP
used to date is required)
with the ability to use any kind of PVPP ma-
terial regardless of the supplier.
Contact
Herman Miseur | KHS Benelux B.V., Breda , the Netherlands
Phone: +31 (76) 572-3234
Email: herman.miseur@khs.com
 Spotlight: the innovators at
Martens Brewery
Martens Brewery in Belgium has invested in innovative KHS
technology on a number of occasions, securing itself a pole posi-
tion on the competitive beer markets of the world. Examples:

2003 Ultramodern, non-returnable KHS PET bottling line

based on an innovative, one-way PET concept is
developed for German discounter Aldi
2009 Martens is one of the first breweries worldwide
to apply InnoPET Plasmax barrier coating technology
to PET beer bottles
2010 Martens buys one of the first KHS Innocheck EBI empty
bottle inspection systems
2011 Martens orders the newly developed KHS Innofill
KHS new Innopro ECOSTAB system Glass filler and KHS Innopro ECOSTAB pilot machine
for the regenerative stabilization of beer
for regenerative beer stabilization.
permits a continuous output 24/7.
Solutions for sectors

a
M ile sto n e

Rmerquelle invests in a KHS ultraclean system as the first milestone

in the centralization of its activities / The Coca-Cola Hellenic Austria
subsidiary has high expectations of hygiene, quality, and environmental
friendliness. KHS has found a solution which meets all expectations
and offers many practical advantages.
competence 02.2012

LEFT Patrick Misch, supply chain director of
Coca-Cola Hellenic Austria
BOTTOM The new ultraclean filling line bottles
sensitive products, such as still mineral water
and near-water beverages, as well as carbonated
mineral water.
W
ere investing in the most up-to-
date water bottling plant in Europe,
stresses Barry OConnell, general director of
Coca-Cola Hellenic Austria. He is referring to
the new KHS ultraclean line which is as ide-
ally suited for bottling sensitive products,
such as still mineral water and near-water
beverages, as for carbonated mineral water
and soft drinks and provides the company
with a whole range of welcome advantag-
es (see Overview: what the line offers in prac-
tice). The system was recently installed at the
plant of Hellenic subsidiary Rmerquelle, the
best-known Austrian mineral water brand, in
Edelstal in the Burgenland.
Here, the group concentrates its pro-
duction and logistics activities in an area of
350,000 square meters. There was previous-
ly a second site in Vienna which produced
other Coca-Cola Hellenic Austria brand prod-
ucts. However, the successfully growing com-
pany is unable to expand further in Austrias
capital city. The administration has therefore
been left in Vienna, while Coca-Cola Hellenic
68/69
Austrias production and logistics units have
been expediently relocated to the nearby
Austrian province of the Burgenland. Patrick
Misch, the supply chain director of Coca-Cola
Hellenic Austria, explains, Were investing a
total of 40 million in Edelstal and creating
150 new jobs there.
After all, the location has a very long tra-
dition. People as far back as the Romans have
taken advantage of the powers of this natu-
Even the Romans
recognized the powers
of the spring
ral spring water which is still very much ac-
tive. Long after the last Roman had supped
from its source the mineral water was made
available in bottles for the first time in 1948.
Since 2003, Rmerquelle has been part of
Coca-Cola Hellenic Austria which holds a ma-
jority interest. The group employs around
1,100 people in the country and supplies
brand beverages to more than 50,000 food
outlets and restaurants, and therefore to
around 8.4 million consumers. In addition
to international classics, such as Coca-Cola,
Coca-Cola light, Fanta, and Sprite, the prod-
uct range includes regional brands such as
Rmerquelle and brands like Nestea which
are bottled under license.
Group with 40,000 employees
Coca-Cola Hellenic Austria is in turn a subsid-
iary of the Coca-Cola Hellenic Bottling Com-
pany with headquarters in Athens. With
around 40,000 employees in a total of 28
countries, the overall group is the largest bot-
tler of Coca-Cola Company products in Eu-
rope and one of the most important in the
world. All told, Coca-Cola Hellenic supplies
about 570 million people with approximately
two billion unit cases each year (1 unit case =
5.678 liters).
Solutions for sectors

RIGHT The Innoket 360 S roll-fed labeling machine: compact design,

high process quality, robust, and user friendly.
BOTTOM The InnoPET Blofill stretch blow molder/filler monoblock
with integrated preform sterilization.

Patrick Misch sees it this way: As a mineral
water bottling plant which has always had
an enterprising approach, Rmerquelle ex-
cellently fits in with the innovative Coca-
Cola Hellenic Group and its strategy of
being a complete supplier of non-alcoholic
beverages to its markets. The company offers
its particularly balanced mineralized water in
still, mild, and sparkling varieties. Consumers
hold it in high regard as a premium mineral
water which was awarded the Superior Taste
Award by the renowned International Taste &
Quality Institute in Brussels in 2011. The mar-
ket share in the hospitality trade is 45%, clear-
ly a pole position. With a market share of just
under 15%, Rmerquelle mineral water holds
third place on the Austrian retail market.
Rmerquelle is particularly successful
with the Rmerquelle emotion product line,
which is based on a combination of mineral
water and natural fruit extracts and com
prises eight different flavors. This enables the
company to hold a leading position in Aus-
tria for near-water beverages with a market
share of an outstanding 42%. But thats not
all. The fresh brand Freche Rmer, a near-wa-
ter product, has recently become available
under the emotion label as a childrens drink.
Susanne Lontzen, press spokesperson for
Coca-Cola Hellenic Austria, explains the im-
mediate success of this beverage creation.
This combination of Rmerquelle mild, with the very forefront with innovative technical so-
its balanced mineralization and a light effer-
vescence, with a fruity base gives young con-
sumers what they want without losing sight
of parents expectations.
Three criteria one solution
Be that as it may, the new ultraclean system
is suitable for all filling situations. Rmer-
quelle currently processes mineral water and
near-water beverages in 0.33-liter, 0.5-liter,
and 1.0-liter non-refillable PET bottles with
a capacity of 28,000 bottles per hour on this
KHS turnkey line. The task for KHS was to
provide quality, hygiene, and environmen-
tal friendliness three criteria which the KHS
system quite obviously fulfils. As a techno-
logical leader were setting new standards
with this line," says Patrick Misch. This is a
win-win situation for both the company and
the environment.
Rmerquelle is the first company in the
world to put its trust in an InnoPET Blofill stretch
blow molder/filler monoblock with integrated
preform sterilization. Were pleased to be at
lutions in which we see real additional bene-
fits, says Misch. Thanks to the brand-new pro-
cess we can work even more sustainably and
reduce costs. And his view of the future? This
line arms us for all future eventualities and en-
forces the aspects of quality and sustainabil
ity which are so important for our customers.
How could it be any better ...
Contact
Edgar-George Petsche | KHS GmbH, Bad Kreuznach,
Germany
Phone: +49 (671) 852-2514
Email: edgar.petsche@khs.com
Katrin Goldhahn | KHS Austria GmbH, Wiener Neudorf
Phone: +43 (2236) 62-510
Email: katrin.goldhahn@khs.com
competence 02.2012 70/71

Overview: what the line offers in practice

Area/process Special features Benefits

The KHS InnoPET Blomax Series IV stretch blow molder

Sterile chamber Preform sterilization Saves up to 2,000 Nm/h of sterile air and up to 400 kg/h of steam
compared with bottle sterilization

Preform heating With near or shortwave infrared The small oven and NIR save space and reduce waste;
radiation (NIR) short heat-up reduces energy costs

Bottle production Servo-motor-controlled stretching Maximum precision during stretching enables ultra-lightweight
process bottles to be produced; the variable stretching speed independent
of the machine speed enables high filler flexibility

The Innofill DRV filling system for carbonated and non-carbonated beverages

Filling Swirlers No spray elements in the bottle; high flexibility independent of

the bottle mouth; no changeovers; beverage is reliably guided to
the inside walls of the bottle which prevents excessive foaming

The Innopro Paramix C two-component blender

Blending system Two-stage vacuum spray deaeration Precise dosing according to recipe

Measurement technology Product data at the press of a button Accurate Brix and CO values

The Innoket 360 S roll-fed labeling machine

Cutters Self-sharpening Precise label cut, less downtime

Vacuum drum Segmented, ultralight Convenient, fast format part changeovers

Gluing roller shell Induction heating with sensors Precise temperature control conserves resources

Overlap correction Simple operation Correction can be carried out during operation

The Innopack Kisters SP 050 Basic and SP 035 Basic shrink packer

Eco shrink tunnel Gas instead of electric heating Saves up to 50% of energy costs; reduces CO emissions by
up to 60%

The Innopal PB1(N)H palletizer

Layer centering Automatic; all-round Perfect layer patterns; gentle product handling; high overall
stability; quick changeovers

Drive concept Servo motors, toothed belts, Ultrasmooth operation; minimal wear; high availability
and robot PC control

Patrick Misch, supply chain director of Coca-Cola Hellenic Austria, sums it up when he says, Our new KHS turnkey line does exactly what
KHS promised. Its extremely sustainable, gives us innovative leadership and cost advantages with its many extras, and also delivers
excellent product quality. And what we also particularly like about KHS is the outstanding service. We feel were in the best of hands.
Solutions for sectors

The One4Two-System

A
combinedsystem
for kegs
For the first time, HEINEKEN relies on the KHS Innokeg Till
One4Two system with great success
/
With immediate effect, time-consuming changeovers and replacement work
on kegs with different fitting types are a thing of the past. And whats more,
the new system is also suitable for existing KHS keg equipment.
Efficiency is the key!
competence 02.2012 72/73

I t happened in Nizhny Novgorod. At this

Russian site HEINEKEN recently placed its
trust in revolutionary keg technology from
KHS at the groups Volga Brewery with suc-
cess right down the line. The patented KHS
Innokeg Till One4Two handling head pro-
cesses two different types of fitting simulta-
neously. This was not previously possible, call-
ing for time-consuming changeovers from
kegs with basket fittings to kegs with flat fit-
tings or vice versa, for example. The centering
cones and fitting plungers in both the wash-
ing and racking heads had to be changed.
Finally, additional CIP cleaning was also
required.
Thanks to One4Two, such changeover
times and costs are now a thing of the past
and system efficiency is significantly in-
creased. Matthjis Dietvorst, the general man-
ager of Volga Brewery, puts it in a nutshell:
Weve had a lot of positive experience with
the One4Two system. Other HEINEKEN sites
in Russia and also worldwide can now benefit
from this successful pilot project.

TOP The Innokeg Till Transomat 3/1 Duo processes both 30 and 50-liter kegs at Volga Brewery.
BOTTOM In the One4Two system two fitting plungers are fitted directly
Positive experience at inside one another.

HEINEKEN

The details are as follows. In Nizhny Novgorod
the company racks 30 and 50-liter kegs with
the proven Innokeg Till Transomat 3/1 Duo
keg line (up to 140 kegs per hour) using the
latest DFC or direct flow control filling tech-
nology. Advantages of this system which have
already been realized include maximum rack-
ing accuracy, great savings potential for the
pressurization gas, minimum amounts of
spray product, and extremely gentle product
treatment. The only drawback, which relates
generally to all HEINEKEN production facili-
ties, is that the keg containers for internation-
al HEINEKEN premium beer have basket fit-
tings, whereas kegs with flat fittings are used
for other brands. This had the aforementioned
irritating consequence of wasting at least one
hour of production time in each case.
Comparatively little effort was involved
in the installation of the One4Two system,
however, which immediately delighted the
brewery managers. Step one involved replac-
ing the cleaning and racking heads. Step two
was to modify the pipe system. In step three
the electrical equipment was connected up
to the new system. The whole conversion
phase took only a few days, praises produc-
tion manager Sergei Dolinskiy. We were
then able to carry on with production with in-
creased system efficiency. This was a step that
was really worthwhile.
The technology used in Nizhny Novgorod
in brief:
In the One4Two system two fitting
plungers are fitted directly inside one
another.
T
 he outer plunger is used for flat fittings,
the inner plunger for basket fittings.
P
 lunger geometries fit inside one an
other exactly; all parts can be perfectly
rinsed and cleaned.
T
 wo movable half-shells ensure the nec-
essary centering of the keg fitting to its
outer contour.
T
 wo pneumatic cylinders align the center-
ing cone with the appropriate radius of
the fitting to be processed in each case.
Solutions for sectors

Options with two kinds of fittings

Increasing globalization, brewery takeovers, and new products in the portfolio:
more and more frequently, kegs with different fittings have to be processed from one day to the next.
Several options are available.

RESULT
Option Significant changeover costs
Change kegs Common
Considerable effort

FITTING TYPES

RESULT

Option Long-term costs

Additional plunger +
Different Changeover delays
centering cones
Additional CIP cleaning
FITTING TYPES (sterilization)

RESULT

One-time investment
Option Different,
but no
The One4Two system No changeovers
format parts

FITTING TYPES
No additional
CIP cleaning

Important: The One4Two system can be easily incorporated into existing KHS keg equipment (in fully automatic lines as
well rotary or semiautomatic machines, such as the Innokeg Till Keg Boy C2).
competence 02.2012 74/75

Sergei Dolinskiy, production manager at Volga Brewery (left),

and Roman Astanin, Volga Brewerys packaging manager,
confirm that The One4Two-System significantly increases plant
availability.

When opened, the half shells center the

dimensionally larger flat fitting; when
closed, they harmonize perfectly with
the smaller basket fitting.
A
 keg ID tag, such as a transponder, en-
ables on-the-fly changeovers between
basket and flat fittings to be relayed in
advance, for instance (Volga Brewery
presorts its kegs; pressing a button on
the operating terminal is all thats
needed to change fittings over).
A
 lso conceivable is installation of a laser
scanner to detect the fitting before the
washing and racking process, and pro-
vision of information relating to the re-
spective keg to the washing and rack-
ing heads.
The highest recognition comes from Roman
Astanin, packaging manager at Volga B
rewery.
This is a well thought-out system, albeit one
which requires more maintenance than be-
fore. However, the reduced changeover times
far outweigh this small additional effort. And Irkutsk, Novosibirsk, Sterlitamak, Kaliningrad,
general manager Matthjis Dietvorst empha and Nizhny Novgorod. Local Volga Brewery
sizes, As we see it, with this system, innova- has been considerably modernized in recent
tion and simplicity go hand-in-hand. years, and currently produces eight different
These are decisive conclusions, and typ- brands of beer, from HEINEKEN to nation-
ical for one of the major brewing concerns al premium beer brands, such as Bochkarev
worldwide, with more than 125 breweries in and Doctor Diesel. Sales of the companys re Contact
over 70 countries and sales of almost 150 mil- gional beers, such as quality brands Okskoye, Andreas Krieg | KHS GmbH, Bad Kreuznach, Germany
lion hectoliters. HEINEKEN brews more than Tri Medvedya, and Okhota, are also outstand- Phone: +49 (671) 852-2647
200 styles of beer within the group. Inciden- ing. At the same time, with a share of 53%, Email: andreas.krieg@khs.com
tally, the concern has become well estab- the PET bottle is the most important contain- Alexander Burenin | KHS GmbH Moscow office
lished in Eastern Europe, particularly in Rus- er. This is followed by the glass bottle with Phone: +7 (495) 783 8100-1017
sia, with a market share of 12% and eight sites 25%, and the can at 17%. With increasing im- Email: alexander.burenin@khs.com
in St Petersburg, Khabarovsk, Yekaterinburg, portance, kegs account for 5% of production.
Special: the century of illumination

LED
The light of the
future
Tiny yet attractive and efficient / In our day and age all companies face
the challenge of conserving our dwindling resources. One tiny component,
the light-emitting diode or LED, can make a big contribution here.
Its ability to save energy and CO emissions alone makes it the light of the future.
This innovative technology is also creating plenty of added value in many other sectors, too.
Bring on the lights!

W eve all seen Tower Bridge in London at least

in pictures. During the Olympic Games in 2012
the city landmark was the focus of attention for billions
of viewers around the world, the five Olympic rings sus-
pended between its distinctive twin towers. At night thou-
sands of lamps provided a fascinating spectacle, bathing
the bridge in a brilliant white light or in the red, white,
and blue of the Union Jack. This display was created by
an innovative technology that, like Edisons light bulb, is
completely revolutionizing the lighting industry: the LED
or light-emitting diode.
LEDs are the shooting stars of our modern illuminants.
They are conquering the world of light, from the brand-new
stadiums erected for the European football championship
2012 in Poland and the Ukraine to the historic Louvre in
Paris, from the Empire State Building in New York to Burj
Khalifa in Dubai, from the image-boosting light designs of
industrial buildings through intelligent lighting systems in
production shops to feel-good offices. LED lighting systems
are being used everywhere and gradually replacing the
conventional light bulb. The advantages of these minia-
ture beacons really are immense, and they are so versatile
that light designers, architects, and building contractors
have recognized that they are bringing about a turning
point in the generation and utilization of light.
Since Thomas Alva Edison perfected the light bulb
around 130 years ago electric light has become a fixed
feature of our everyday lives.
competence 02.2012
Like the air we breathe, we now take electric light for
granted. The extensive part of the world that has electric-
ity has been living and working with artificial light for so
long that it no longer even thinks about it. Thats a mis-
take. For were paying a huge price for it both economi-
cally and ecologically.
According to a study carried out by the International
Energy Agency (IEA) light consumes 20% of all electricity
generated worldwide. Depending on what type of illumi-
nant is used, huge savings can be made. By way of compar-
ison, according to the present state of the art LED lamps
have a yield of 100 to 120 lumens per watt (lm/W) and are
thus much more efficient than standard light bulbs with
10 to 15 lm/W. As a rule, more than 80% of our electricity
76/77
and money is thus spent on light without generating any
value for the company or client. On the contrary, it actually
harms the environment.
The benefits of the LED (I): energy efficiency
Accordingly, the McKinsey Company estimates that if LED
lamps were used in offices and industry, there would be
an annual potential saving of 4.4 billion in the European
Union alone. With prices steadily rising for our ever di
minishing energy reserves, more and more companies are
realizing how important it is to invest in energy efficiency.
And theyre not waiting for stricter environmental direc-
tives and laws to force them to switch to more efficient
lighting systems; theyre acting now.
Special: the century of illumination
LEDs in practice: United States Cold Storage. One of
these is the USAs largest cold storage and logistics com-
pany, United States Cold Storage (USCS). USCS can count
a number of renowned American food producers and in-
ternational brands among their customers. In order to
reach the ambitious efficiency and sustainability targets
set by USCS for its new cold warehouse in Hazleton, Penn-
sylvania, the companys previous electricity consumption
was recorded and analyzed with a view to future possi-
ble savings. After carefully weighing the various alterna-
tives, the project group finally decided to install an intel-
ligent, LED-based lighting system. The team achieved the
following results:
Lighting costs cut by 90%
CO emissions down by 93%
Additional costs for air conditioning due to heat
emitted by the lights now avoided, and
Maintenance costs minimized thanks to the long
LED service lives.
ABOVE Wilkie Edge, Singapore: light design
with 546 computer-controlled LED modules
LEFT Tower Bridge, London: thousands of LEDs
lit up for the 2012 Olympics.
The payback period for the new lighting system is less than
fifteen months.
LEDs in practice: Le Meridien Hotel. Another example of
how lighting has been optimized using LEDs is the mod-
ernization of the old-established Le Meridien Hotel in
Rio de Janeiro. When the hotel joined the internation-
al Windsor hotel chain, improving sustainability and en-
ergy efficiency was a top priority. The modernized hotel
with an area of 30,000 square meters spread out across 39
floors has 545 rooms, three restaurants, a spa, two pools,
and eight conference suites.
In developing the lighting concept for Windsor Atln-
tica, as the hotel is now called, the prime concern was to
use products that not only provided enough light but
also considerably reduced costs for maintenance and the
amount of electricity used. The answer was to replace all
of the 40-W light bulbs previously used with efficient 8-W
LEDs in a classic lamp design. The result is an energy sav-
ing of 80% at the same level of illumination.
competence 02.2012 78/79

Good to know: types of lamps

Type Light yield Service life Color Startup time
rendering
Incandescent light bulb 5 750 > 90 Ra Immediately
Oldest type of electric lamp. Electricity heats a tungsten filament in a 15 lm/W 1,000 h
glass bulb vacuum that then glows.

Halogen lamp 14 2,000 > 90 Ra Immediately

Improved light bulb with a halogen gas mix in the glass bulb. 25 lm/W 4,000 h

Fluorescent lamp 50 8,000 80 100 Ra Fast

Inside the lamp, filled with mercury vapor at a low pressure, the gas 105 lm/W 20,000 h
mixture is ionized (made conductive) by a high electrical charge at
two opposite electrodes. Fluorescent lamps contain toxic chemicals.

Energy-saving bulb 35 8,000 > 82 Ra Fast

A compact fluorescent lamp or CFL. Here the electrodes are not 75 lm/W 15,000 h
opposite one another but slotted into a base in the shape of the light
fixture on the same side. CFLs contain toxic chemicals.

LED module 80 40,000 > 90 Ra Immediately

Light-emitting diodes can only be used for lighting purposes if they 120 lm/W 100,000 h
form a module on a printed circuit board. One special module is
whats known as a retrofit lamp. It has the same shape as a tradition-
al light bulb and can be used in existing light fittings.

lm/W = lumens per watt (light yield/efficiency); h = hours; Ra = color rendering quality, best value = 100.

In addition, the LEDs used generate practically no heat,
thus reducing the ambient temperature and cutting
down on the amount of air conditioning needed. Their
extremely long service life of 25,000 hours also means a
much lower expenditure for maintenance.
The benefits of the LED (II):
multiple design options
Just ten years ago we were only familiar with LEDs as tiny
light sources for electronic displays. In an extremely rapid
development these miniature bulbs have practically dou-
bled what they can do every two years, enthuses Munich
light designer Josef Maximilian Wollinger. High-quality
LEDs are now so developed that they can also cope with
sophisticated lighting tasks, opening up completely new
avenues in lighting design. Wollinger specializes in creat-
ing individual lighting effects for TV and film productions
the atmosphere that ensures that not all colors agree in
the dark. Hes now being consulted by architects wanting
to create certain effects with light in single rooms or en-
tire buildings. Brand-specific light design is the term ex-
perts give to lighting that accentuates the appearance of
a building and communicates the brand identity as a cor-
porate message. At Wilkie Edge, a commercial complex
in Singapore, brothers Jan and Tim Edler have created a
symbiotic link between the billboards already integrated
Special: the century of illumination

Information and contacts

Nimbus Group pr@context-kommunikation.de
realities:united Jan Edler je@realU.de
Josef Maximilian Wollinger mail@wiwoclan.de
Fraunhofer IAO presse@iao.fraunhofer.de
GE Deutschland vera.weissl@ge.com
Info-Plattform www.licht.de
Peter Andres mail@andres-lichtplanung.de
Bartenbach Lichtlabor info@bartenbach.com

into the faade and the actual architecture of the build-

ing. The effect they call the Architectural Advertising Am-
plifier (AAMP) is a constantly changing media installation
on the faade.
A matrix made up of 546 colored, computer-con-
trolled LED modules transforms the entire glass front of
the office block into an irregularly shaped screen which
emulates the content of the billboard like a collage. In-
stalled in the outer layer of the twin-walled exterior, every
single LED module projects a colored square onto the in-
ner layer of the faade. The sunshades outside the office
windows act as a projection surface. In the evening when
people leave the office, motion sensors give the signal to
close the blinds. Step by step an area of over 800 square
meters is turned into a giant, low-resolution screen. The il-
luminated square windows of the offices still in use punc-
tuate the digital image and let people see whats going
on inside. There is thus a dynamic interaction between the
architecture, use, and medium of the building, creating a
choreography of light.
Jan Edler sees a temporary link between art, architec-
ture, and advertising in his installation. Perhaps AAMP
can contribute to the current discussion on the use of
large-scale advertising as an undeniable part of todays
urban reality, he says.
Lighting can emphasize existing structures while dis-
playing a sophisticated quality of its own, as the first build-
ing in the world that has been lit entirely by LEDs since
2007 proves. The Chamber of Commerce in Hamburg has
been at the center of the citys commercial activities for a
good 340 years. When the Chamber was restructured in
keeping with the guidelines for the preservation of his-
toric monuments, the planners included a new complex
The Chamber of Commerce in Hamburg: a building
within a building with over 160,000 LEDs
as a building within a building. This is lit exclusively by LED
modules designed by Stuttgart lighting manufacturer
Nimbus in collaboration with Behnisch Architekten.
Depending on requirements over 160,000 LEDs in
380 quadratic lighting modules either fill the individual
offices with an intense working light or shed weak light
on certain areas to mark the way. Areas in which no one
is working simply remain dark. The building is lit with the
utmost energy efficiency, as only the luminous intensity
actually required is provided," explains managing director
of the Nimbus Group Dietrich Brennenstuhl.
The benefits of the LED (III): lighting quality
Light and color greatly affect how we feel. The way in
which we have developed means that daylight makes us
more active, yet staring into a camp fire calms us down,
says lighting expert Wollinger. He believes that qual
ity LEDs can cover this spectrum very well. They can be
used in many different ways in totally diverse areas of
application.
competence 02.2012 80/81

Unlike light therapy used in medicine, the effects of ad-
equate lighting at work either in the office, production
shop, conference hall, or cafeteria are largely unknown.
Yet its here that companies can exploit what is perhaps
the greatest potential.
Markus Canazei, who researches the effects of light
at the famous Bartenbach LichtLabor in Aldrans in Aus-
tria, thus began investigating the question of whether the
lighting concept in a production shop could increase em-
ployees sense of wellbeing and therefore also productiv-
ity. A one-year field study at Flextronics in Althofen, Aus-
tria, proved that during months with little light personnel
showed fewer symptoms of stress and slept better when
lighting conditions were improved. Productivity also rose
by up to 5.4%.
Continuing this line of study, researchers at the
Example calculation:
LEDs in corridors
Even when used in standard lighting situations, with their high lu-
minous quality and efficient technology LED systems are convincing.
This example shows that the slightly higher cost of investment soon
pays off. It compares the downlighting in a corridor 20 meters long;
the downlights are fitted with CFLs (4 x 26 W) and LEDs (26 W). The
calculation is based on ten years of operation twelve hours a day on
250 days of the year at a rate of 0.21 per kilowatt hour.
Cost in euros
2,400
2,000
1,600

Fraunhofer IAO Institute in Stuttgart have in their Light-

1,200
FusionLab a facility where they can build and assess pro-
totypes of new lighting systems. One of the ideas investi- 800
Break-even point
gated here is the effect of dynamic LED illumination at the 400
office workplace. One example of this is Virtual Sky, a new
kind of ceiling lighting that mimics the rhythm of daylight 01 02 03 04 05 06 07 08 09 10

or of clouds passing across a blue sky. A study carried out Years of operation

in conjunction with the Transfer Center for Neuroscience

and Learning (ZNL) in Ulm shows that user acceptance is
considerably higher in workplaces with an individual, dy- LED
namic form of lighting than in those with conventional, CFL
static light. The first companies have already submitted
requests for the new Virtual Sky, chiefly for their confer-
ence rooms. Total cost of the system in euros

The benefits of the LED (IV): future potential 2,400

LEDs provide fascinating new possible spheres of applica-
2,000
tion that until recently were inconceivable. Even Peter An-
dres, light designer of the year 2012, promotes the pos- 1,600

itive effects for society and the economy. Light has an

1,200
immediate effect. The aim is to make people feel good
wherever they are. Can I concentrate in my office, do I like 800

shopping at a mall, do I keep calm in a hectic airport, or 400

can I relax in a lounge? If I can be put in a suitable mood,
then the planning has been successful. Experience is im- Downlights Downlights
with CFLs with LEDs
portant here but even more so is the willingness to try out
new technical setups. The people of London at least, oth-
erwise so attached to their traditions, have built a bridge Initial investment (price for four lights)
to the future of lighting as we know it. Operating costs (over ten years of operation)
Maintenance costs
Horst Kern/Jrgen Jacobs Source: www.licht.de
In-house news

We look forward to seeing you!

Visit KHS at Brau Beviale 2012
in Hall 5,
Booth 127
Contact: matthias.damm@khs.com

KHS at
Brau Beviale
2012
Best Value: competitive advantages
Once again visitors to Brau Beviale (November 1315 in Nuremberg, Germany) can look for-
ward to a number of innovative developments from KHS. This year the focus will be on A) the
new Innofill Glass Micro filler for medium-sized companies, and B) its new labeling technol-
ogy conceived as a system of modules. In answer to the great demand last year, the experts
from KHS will also be providing detailed advice on C) the many possible upgrades available
for KHS lines and machines. Come and see us, and secure a number of competitive advantages
for your company!
competence 02.2012 82/83

THE INNOFILL GLASS MICRO FOR THE

A LOW AND MEDIUM CAPACITY RANGE
Outputs of 6,00025,000 0.1 to 3.0-liter glass bottles per hour
Specially developed for the medium-sized brewing and soft drinks industries (special version for wine,
sparkling wine, and spirits bottlers)
M
 any components taken from the high-capacity range
Low oxygen beer filling with an extremely low CO consumption
Computer-controlled, single-chamber DPG-ZMS filling system provides the best hygienic conditions
Twin-valve control in use for the first time makes every second gas cylinder and various electronic
components redundant
Compact valve manifold takes up 50% less space.

B MODULAR LABELING TECHNOLOGY

HIGHLY FLEXIBLE
F lexibility, individuality, process quality, reliability, operator friendliness, and a space-saving design
Various labeling techniques integrated into one machine (cold glue, adhesive-pressure,
hot melt, and roll-fed labeling)
C apacity of 10,00072,000 containers per hour
For glass and plastic containers and cans containing from 0.1 to 3.0 liters
Base machine consists of just a carousel and front table (former wide table construction
now redundant)
H
 as excellent accessibility and is quick and easy to clean
Belt drives, mechanically controlled cam rotation, or VarioDrive possible.

C NEW FROM OLD:

UPGRADES TO ORDER
Full service package customers can profit from throughout the entire life cycle of their lines and
machines
Various upgrades right across the board of KHS expertise
Many enhancements possible, from the processing of new bottles and packaging through
innovative filling processes, increased line and machine efficiency, improved hygiene,
and more environmentally friendliness to simplified operating concepts
Original KHS spare parts are matched to each system.
In-house news
The KHS booth at Fispal 2012: over 600 guests
came to the anniversary.
50 years of KHS Brazil
Festival brasileiro
T he success story spanning half a cen
tury began in 1962 (the Beatles were
just starting to conquer the world with their
music) when a partnership for automatic fill-
ing systems was formed with Nashold S/A In-
dustria de Maquinas in Brazil. In June 2012
(the lads from Liverpool have gone down in
the annals of music history) KHS Brazil cele-
brated its 50th anniversary. At its site in So
Paulo measuring over 40,000 square meters
in area (or almost ten soccer fields) and em-
ploying 400 people, the KHS factory chief-
ly manufactures products used in its filling,
rinsing, process, and conveying technology.
Together with the other KHS plants active
worldwide, it supplies local customers with
complete systems and a full range of services.
Several milestones have marked the way
over the past 50 years. In 1974 all activities
were moved to a new site; in 1975 exports
to other countries in Latin America began;
in 1990 filling machines for returnable PET
bottles hit the Latin-American market; and
in 1996 the factory was granted its ISO 9001
certification. And throughout all this time
the product portfolio has been constantly
adapted to meet the changing demands of
the market. KHS GmbH is seen as being a reli-
able partner by a broad customer base across
Latin America, one reason being that it re-
mained active in the country during Brazils
economic crisis.
High market share
KHS market share of filling and packag-
ing technology for the beverage sector in
Brazil is now at an impressive 35%, with
this figure at 30% for South America as a
whole. The economic mainstay is and al-
ways has been the brewing industry, which
accounts for 40% of sales. This is followed
by the soft drinks segment with 35% and
the fruit juice business with 10%. The re-
maining 15% of sales is realized in other
beverage segments and the food and non-
food industries.
The number of visitors who accept-
ed KHS Brazils invitation to its 50th birth-
day party at this years FISPAL in So Paulo
from 1215 June was accordingly high.
Around 600 guests from many countries in
Latin America seized the opportunity to con-
gratulate the management of KHS and their
employees and announce that they were
looking forward to continuing a trusting
partnership.
The managing directors of KHS Brazil, Al-
cides Vieira, Roberto Giampietro, Franz Beis-
sel, and Fernando Manente, were thus op-
timistic about the next few years. All expert
forecasts for Brazil and the Latin-American
market also see the consumption of bever-
ages growing. A particularly strong increase
is expected for water, carbonated soft drinks,
and non-alcoholic beverages, such as health
and energy drinks.
competence 02.2012 84/85

CBE in China Trade show review New at KHS Corpoplast

NEW FACTORY EXPO PACK in NEARING

NEW MONOBLOCK Mexico COMPLETION

G ood luck! These wishes are addressed

to the new production site in Suzhou in
China, which CBE or Corpoplast Beverage
Equipment Company Limited is currently
starting up. This is where CBE is to be manu
facturing machines powered by KHS in the
new AQUABLOC series that is specially tai-
lored to the needs of Asian customers who
bottle water in PET at low to medium capacity.
KHS expects great potential for the future,
particularly in the continuously growing wa-
ter market in Asia. Professor Dr.-Ing. Matthias
Niemeyer, the CEO/CTO of KHS, summarizes.
The new Suzhou site will meet the specific re-
quirements of the Asian PET market, which is
showing above-average growth. At the same
time, both sides will benefit from proximity to
the customer and short transport distances.
T hings were busy at the KHS booth at
EXPO PACK 2012 in Mexico City, held be-
tween June 26 and 29. This year the definitive
focal points were the Innofill Glass platform
recently developed by KHS and the innovative
Innopro ECOSTAB beer stabilizer. While visi-
tors in the high-performance bottling trade
were primarily attracted to the Innofill Glass,
the Innopro ECOSTAB was of great interest to
medium-sized companies. As a reminder, the
Innofill Glass is heralding a new dawn of fill-
ing technology by providing even better fill-
ing quality and potential for considerable
reductions in cost. The Innopro ECOSTAB is
revolutionizing regenerative beer stabiliza-
tion, particularly for small and medium-sized
companies with beer outputs of 400,000
hectoliters per year or less.
T he new production shop for KHS Corpo-
plast in Hamburg, Germany, is nearing
completion very fast. This April the founda-
tions were laid for the new 2,500 square-meter
hall, with production scheduled to start this
year. The company desperately needs the ex-
tra space, as the growing demand worldwide
for the InnoPET Blomax Series IV stretch blow
molder recently developed by KHS Corpoplast
has noticeably increased, keeping the order
books full to bursting over the past business
year. By the year 2015 KHS Corpoplast aims to
double its 2011 production capacity through
further investment.

KHS Press Circle

W HEN JOURNALISTS
ARE FULL OF PRAISE

T hen you should usually exercise caution!

As we all know, the writing profession has
its ways of gaining information. But this time
things were different. On the occasion of the
annual KHS Press Circle the management of
KHS issued an invitation to its production site in
Kleve, Germany. Here and at Bavaria Brewery in
nearby Lieshout in the Netherlands, a loyal KHS
customer since 1987 with a wide range of KHS
filling and packaging technology in operation,
members of the press in the beverage, pack-
aging, and food industries could quite openly
glean information on the latest in final packag-
ing. The Executive Management Board of KHS
presented technical innovations, shed light on
the development of the company, revealed its
sales successes, explained developments within
the production network, and answered all the
questions those present wished to ask. The
journalists unanimous verdict was that it was
a very interesting event which left nothing to
be desired as far as information is concerned.
This is the kind of journalistic praise you can The new production shop at KHS Corpoplast
is as big as half a soccer field.
accept without any misgivings
In-house news

50 years at KHS a member of the KHS works council since

1984, acting as its chairman for the last 25
THANKS, years. Anniversaries like these are thus major

Helmut Weber! events. Says Weber, Its rather unusual in our

day and age to celebrate 50 years working for
the same company. When I look back, I made
the right decision in staying loyal to KHS all

T his is a very special anniversary indeed:

this year Helmut Weber, works council
chairman at KHS GmbH and employee repre-
sentative on the Supervisory Board at Salzgit-
ter AG, is celebrating 50 years of working for
KHS. Always active, Mr. Weber took up his oc-
cupation as an apprentice mechanic in 1962,
then working for many years as a machinist
at the assembly plant and in filler construc-
tion in Dortmund. Helmut Weber has been
these years.
In his eulogy Professor Dr.-Ing. Matthias
Niemeyer, the KHS CEO/CTO, emphasized,
Friedrich Nietzsche once said A profession is
the backbone of life. This quote suits Mr. We- A very special anniversary (from left to right):
Anke Fischer, CFO/CHRO, Helmut Weber,
ber very well, as he has always been commit- Prof. Dr.-Ing. Matthias Niemeyer, CEO/CTO,
ted to the wellbeing of our personnel yet has and Marc Hartmann, COO.
always just as clearly kept the survival of the
company in his sights. And for that I would
like to sincerely thank him.

Awards for KHS competence

THREE PRIZES

I ssue 2/2011 of KHS competence has been

Award-winning ceremony in Berlin:
KHS competence is presented with the silver
Best of Corporate Publishing Award
in the Industry category.
given top ratings by various communica-
tions experts of renown no less than three
times. At the FOX AWARDS, the first award
for efficiency in corporate publishing, the
magazine was presented with the special
FOX VISUALS prize for customer and em
ployee magazines. The Corporate Communi-
cation Institute or CCI of the Faculty of Design
at Mnster University of Applied Sciences as-
sesses visual anchors in print media according
to 50 different criteria which include layout,
the use of typography, and graphic language.
The institute also evaluates the business re-
ports issued by Germany companies for the
annual manager magazine competition.
Out of 173 submitted media, a top-
notch jury made up of scientists and practical
thinkers at various agencies and compa-
nies also gave KHS competence the SILVER
FOX AWARD for extraordinary efficiency
in development, range and quality of distri-
bution, lead generation, sales impulse, and
brand conformity. The overall impression
the pleasure and curiosity generated in using
such media also influences the total num-
ber of points.
And finally, KHS customer magazine
won a BCP silver at the Best of Corporate Pub-
lishing Award in the Industry category. With
over 600 publications submitted, BCP is the
largest corporate publishing competition in
Europe. Since 2003 Forum Corporate Publish-
ing (FCP) has been awarding the BCP to the
best company publications issued in the Ger-
man-speaking parts of the world.
competence 02.2012 86/87

KHS employee was part of the Games KHS competence

OLYMPIC
W RESTLER
PUblisher
KHS GmbH, Dortmund, Germany

Editors
KHS: Matthias Damm, Manfred Rckstein; Friederike Arndt, Bonn; jj-media, Cologne;
Markenkern GmbH, Munich

K HS took an active part in this years Olym-

pic Games in London. Farzad Tarash,
project manager at KHS Asia/Pacific in Mel-
Graphics
Konzeption +Design, Quass von Deyen/Schneider/Voss, Cologne

bourne, entered the Mens 60 kg Freestyle
Wrestling and reached the 1/8 finals. Tarash is
the only wrestler in Australia who was able to
qualify for this discipline. The likeable sports-
The German version of the magazine has been translated into English, French, and Spanish by
man says, Taking part in the Olympic Games
has always been my goal. Looking back, the
strenuous training over the past few years has
more than paid off. Farzad Tarash was born
into a family of wrestlers; his father was one
of the top wrestlers in his native country of
Iran. Incidentally, Mehrdad Tarash, Farzads
brother, only narrowly missed taking part in
the Olympics this year.
CONTRIBUTIONS
Michael Beier, Michael Beisel, Volker Borngrber, Alexander Burenin, Ludwig Clsserath,
Kecheng Ding, Werner Gessner, Katrin Goldhahn, Karl-Heinz Klumpe, Andreas Krieg,
Herman Miseur, Stefan Muhs, Edgar-George Petsche, Ralph Pohl, Christopher Stuhlmann,
Tung Minh Tuan, Lothar Wilhelm, Armin Wille
TRANSLATIONS
Fachbersetzungen CP MacKusick
/
Photos illustrations
Timo Beylemans; Brouwerij Haacht; Foto Gronauer; GE Deutschland; Cornelis Gollhardt;
JSC Georgian Beer Company; Sylvia Niggeloh; Nimbus-Group; realities:united, Berlin;
Frank Reinhold; Jrg Schwalfenberg, shutterstock (Thampapon); Spendrups Bryggeri
This information is non-binding. Only the technical specifications of our quotes are
determinative with regard to design and scope of delivery. Subject to design modifications.
INFORMATION FOR ORDERING
KHS Competence is published in English, German, French, Spanish, and Russian.
Those interested can order further copies of the magazine at www.khs.com.

Addresses
KHS GmbH KHS Corpoplast GmbH KHS Pacific Pty. Ltd.
KHS on YouTube Juchostrasse 20 Meiendorfer Strasse 203 P.O. Box 378
44143 Dortmund, Germany 22145 Hamburg, Germany 13 Freight Road

EXCLUSI V E Phone: +49 (231) 569-0

Fax: +49 (231) 569-1541
Phone: +49 (40) 67907-0
Fax: +49 (40) 67907-100
Tullamarine, Vic. 3043, Australia
Phone: +61 (393) 35-1211

PRESENCE
Planiger Strasse 139 147
55543 Bad Kreuznach, Germany
Phone: +49 (671) 852-0
Fax: +49 (671) 852-2411
Fax: +61 (393) 35-1331
KHS Plasmax GmbH Email: info@khspacific.com.au
Meiendorfer Strasse 203
22145 Hamburg, Germany KHS Asia Pte. Ltd.
Phone: +49 (40) 67907-364 371 BEACH ROAD
Fax: +49 (40) 67907-353 #25-08 KEYPOINT
199597 Singapore

K HS technology and engineering is now Enzingerstrasse 139 KHS UK Ltd. Phone: +65 (6560) 9313
67551 Worms, Germany Unit 6, Monkspath Business Park, Fax: +65 (6560) 9910
featured in moving pictures on YouTube. Phone: +49 (6247) 97-0 Highlands Road, Shirley, Solihull Email: info@khsasia.com
Fax: +49 (6247) 97-3300 West Midlands B90 4NY,
Those who access the KHS YouTube site can
Great Britain KHS Machinery Pvt. Ltd.
gain an immediate impression of how KHS Ruwoldtweg 14 Phone: +44 (121) 713-6900 Near Hirapur Chowkadi,
22309 Hamburg, Germany Fax: +44 (121) 713-6935 Vatva - Mehmdabad Highway
innovative, customized systems are imple Phone: +49 (40) 63703-0 Email: info@khs.com 382435 Ahmedabad
mented in practice. All films also include brief, Fax: +49 (40) 63703-36150 Gujarat, India
KHS USA, Inc. Phone: +91 (79) 66100000
user-oriented descriptions. With its own You- Boschstrasse 13
880 Bahcall Court Fax: +91 (79) 66100010
Waukesha, WI 53186, USA Email: khs@khsindia.com
Tube channel KHS is taking the important 47533 Kleve, Germany
Phone: +1 (262) 797-7200
Phone: +49 (2821) 503-0
step of embracing the social media network, Fax: +1 (262) 797-0025
Fax: +49 (2821) 503-503 Email: mike.brancato@khs.com
thus extending its online media presence, and
5501 N. Washington Blvd.
providing a virtual forum for all of its product Sarasota, FL 34243, USA
and company videos. Phone: +1 (941) 359-4000
Fax: +1 (941) 359-4043
www.youtube.com/KHSGMBH Email: info@khs.com Email: john.turner@khs.com
30 1992-01-997/2 1012 DR