KHS Journal 04_06 e

English4° 2006

journalKHS

KHS IN CHINAMilestone in Internationalization

+ Majority interest in GLM2 + Six leading companies order

cutting-edge KHS technology+ Successful at China Brew & Beverage + Landmark brewers’ seminar in Wuhan

Fruvita: Innovative ACF for juices

The Fruit King

Sinalco: Keg line assists meteoric growth

A Brand Returns

KHS Innoclean SEC: Smaller units score big

High-Tech at Its Finest

KHS Journal 04_06 e 18.12.2006 10:59 Uhr Seite 1

We at KHS, support our globally active customers

as partners in every respect.

editorial

»«

Dear Readers,

The world is becoming ever smaller. No doubt, you will have come across this saying. During my more than 40 years in sales at KHS, Iliterally saw it happening little by little. For example, not all that long ago my trips between countries and continents involved exten-sive and tedious preparations and visits to different cultural spheres.Today this has changed radically. Due to faster means of transportation and in some cases because of fewer formalities, trips havebecome much shorter. In addition, globalization is a catchphrase on all continents, leading to cultural and interest spheres growingcloser together. Globalization represents a tangible and experiencable spirit of our age. We are all turning into cosmopolitans, whileof course retaining special local characteristics. Global human development sets the parameters for the companies on our globe. Thedegree to which companies can be successful depends on the degree to which they are prepared to respond to their customers. Bev-erage, food, and non-food companies are therefore pursuing an increasingly global strategy involving activities spanning all continents.We at KHS, support our globally active customers as partners in every respect. KHS not only calls itself a globally acting company, overthe years it has in fact become a worldwide company and acts accordingly on a daily basis. This means wherever our customers intendto explore new markets – KHS is already there and can provide not only complete and state-of-the-art filling and packaging solutions,but also local and global know-how. Today KHS has more than sixty sales and service bases on all continents. In addition, we haveachieved comprehensive local production presence with six plants in North, Central and South America, India, and now also China, plusour locations in Germany. Our motto: ‘We are always there when you need us, wherever you are in the world or wherever in the worldyou will be in future.’ We want to affirm our vision of KHS as a global market leader and preferred supplier for the packaging industrywith focus on beverage applications and complete lines that meet highest quality standards everywhere. It goes without saying that,in addition to offering essential global know-how, we also take into account special local characteristics and are able to provide localknow-how where required. This is the basis for mutually successful partnerships. Our ‘one face to the customer’ concept underlinesour focus on customer orientation.Do you remember the traditional Latin phrase nomen est omen (true to its name)? I’m deliberately referring to long-standing and well-tried tradition, because without it and without reliance on what has been tried and tested neither globalization nor the future as awhole will be possible. This saying is therefore part of the tradition that KHS has preserved. The name KHS can be interpreted as Know-how, High-tech, Service. In the past, today and in future. It includes a commitment to global presence – and here we’ve come full cir-cle – and gives you assurance that you have a supplier as a reliable partner who has the ideal prerequisites for accompanying you intoa successful global future.

Yours truly

KHS AS A GLOBAL PLAYER – BENEFITS FOR

GLOBALLY ACTIVE CUSTOMERSMaternus Gemmel,

Chief Sales Officer KHS


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contents ° 4°2006 02*03

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people+marketsnews

Customers, Know-how, and Contacts

20 34

task+solutionFruvita in Serbia relies successfully on ACF with dry sterilization The Fruit King

Winzer Krems: Austria’s largest viticultural cooperative has a tradition of innovation The Keg Wine Pioneers

Jazak Mineral Water, Serbia: The slightly different success storyPerfect Connection

The success story of the Stiegl Brewery, Salzburg, goes merrily onRecord in Mozart Year

Voda Voda: Unique overall conceptWater to the Power of Two

Saudi Arabia’s Pepsi bottler with high-performance canning linesSipco Sets an Example

Pepsi-Cola, Iraq: Licensing partners placing trust in KHS equipment6 Lines in 2 Years

KHS keg technology involved in the global comeback of Sinalco A Brand Returns

Bad Driburger Naturparkquellen: Refillable PET plus glassThe Perfectionist

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dialog+opinionInterview with Bernd A. Diederichs, NürnbergMesseFrom a National to a European ‘Family (Af)Fair’

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KHS 2010plus

Interview with Volker Till, KHS’ Chief Technical OfficerStandards Benefit the Customer

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42technology+innovationThe new Innoclean SEC is a gem with twelve impressive advantagesHigh-Tech at Its Finest

Technical terms in practiceFiltration Makes Beer Perfect

Guest at KHSWelcome to Nuremberg

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GLOBAL STRATEGY

KHS AG is strengthening its presence in China and in Asia by tak-ing over majority control of the Chinese company Guangdong LightIndustrial Machinery Plant 2 Ltd (GLM2). As a manufacturer of fill-ing and packing equipment, with headquarters in Shantou in theprovince of Guangdong, the company is positioned excellently inthe Chinese and Asian market. With a sales volume of more than30 million euros, GLM2 is one of the market leaders in the indus-try in China and is building an extensive network in China and Asia.GLM2’s list of customers includes big names in the brewing tradesuch as Tsingtao, C.R.B., Yanjing, Kingway, Harbin, Asian Pacific,San Miguel, Chonqing, Lion, Jingxing, Heineken, and Anheuser-Busch.

By acquiring GLM2, KHS once again points the way to thefuture in the Asian market. Just recently, KHS increased its sharein the Indo-German joint venture KHS Machinery Pvt. Ltd. to 89%.

In addition, construction of a new KHS plant in India is soon to becompleted.

The contracts in China were signed by the partners on August17, 2006. The former private owners sold their 70-percent share ofGLM2 to KHS. Equal shares of the remaining 30 percent remain inthe hands of the two managing owners, who will continue to bemembers of the company management. The transaction is expectedto be concluded within the next few months after the requiredgovernment approvals have been obtained.

The significance of this agreement for all involved is under-scored by Zheng Jiannong, managing owner of GLM2: “For GLM2,the close partnership with KHS represents a milestone in thedevelopment of the company and opens up tremendous oppor-tunities for both partners in Asian growth markets, particularlyin China.”

• Majority participation in Chinese bottling and packaging specialist

• The company acquired is among the market leaders in China

• Markets for bottling and packaging machines are growing in the double digits

KHS GOES CHINA


04*05people+markets ° news

Above Opening of China Brew & Beverage, Beijing: Present in the first row

(3rd from right) – Thomas Scharsing, Director of the China Marketing Region, at

the first joint appearance of KHS and subsidiary GLM2 in China. Below Signing

of the contract (from left): Valentin Reisgen, CEO KHS AG; Zheng Jiannong,

Managing Owner (GLM2).

The numbers confirm KHS’ steadily increasing participation in oneof the most interesting growth markets in the world with the newinvestment in China. The demand for packaging machines for thebeverage industry on the Chinese market alone will grow from about390 million euros (2002) to around 900 million euros in the year2010.

The decisive point: 80% (2005) of this demand is coveredby the domestic industry. The future need for modern technicalsolutions in the beverage industry is clarified by these figures: theyearly beer consumption in China is only 18.8 liters per capita. Ahigh backlog demand is apparent – and predicted. Experts in thebeer sector expect that China will account for 50% of the worldwideincrease in demand for beer within the next ten years.

Valentin Reisgen, Chief Executive Officer of the KHS AG,summarizes the strategy and vision of the Chinese activities of the

KHS group like this: “This partnership largely concludes the devel-opment of our international production network. The local pres-ence continually called for by our global customers is now achievedby our plants in North and South America, India, and China in addi-tion to our locations in Germany. We are convinced that with thisacquisition we are now well prepared for the future globalizationrequirements in our branch of industry. With this move, we willcontinue to be one of the leaders of the market particularly in thegrowth region of Asia.”

KHS LAUNCHES TRAINING FOR CHINESE BREWERS

Education is considered very important in China. That was the experi-ence of KHS and the Wuhan Academy of Brewing Technology when theyorganized a prestigious brewing seminar from May 23 to 26 of this year.More than 100 participants from nearly all the breweries in China followedthe presentations and lectures of the main speaker from the TechnicalUniversity of Munich, Professor Werner Back, and Dr. Martin Krottenthaler,who had an extensive repertoire on offer from the latest in research.

The chief sponsor, KHS, contributed to the success of the eventwith talks by Ludwig Clüsserath, head of the Process Engineering Com-petence center, and Dr. Hartmut Evers, head of Laboratories and Tech-nology Centers. In the focus of their talks (all presentations – to thedelight of the public – in the Chinese alphabet) was current research atKHS, from filtration to hygienic design, ultra-clean filling, beer in PET,to the latest in cleaning technology. The participants and the directorof the Academy, Xu Gong Jin, experienced compelling presentations withmany new discoveries, which will surely continue to contribute to for-ward-looking brewing technology in China. A concluding cruise on theYangste River provided all the participants with the opportunity to expe-rience the quality of Chinese beers.

SEMINAR AT WUHAN ACADEMY OF BREWING TECHNOLOGY2


ALMOST WORLD CUP CALIBER: THE SECOND KHS SOCCER CHAMPIONSHIP

ELBCOAST KICKERS IN THE LEAD

In a hot July of 2006, shortly after the fantastic third-place showing of theGerman nation team at the World Cup, the KHS Soccer Championship was heldfor the second time, with great success. The patron: Maternus Gemmel, ChiefSales Officer of KHS AG. The KHS event also profited from the spirit of the celebrated world spectacle.Brazilian colleagues strengthen one team and even the names of the 16 teamsreflected international soccer fantasies such as Paraguay Labeling Friends, FCDynamo Four-Wheeler, or Final Assembly Jägermeister – guests and players alikeanticipated a big day. From the live broadcast: At 11 AM was the starting whis-tle. The tension skyrocketed around the sports arena ‘Auf dem Bleck’ in Dort-mund-Asseln. During a playing time of 15 minutes each, the KHS teams battledit out to win the trophy – the challenge cup. By late afternoon, the victor hadbeen determined: The Elbcoast Kickers (1:0 against the Final Assembly Jäger-

meister) were celebrated by the enthu-siastic crowd. A lot of fun. KHS’ CEOValentin Reisgen, Maternus Gemmel,and Helmut Weber, Chairman of theJoint Works Council, were gratifiedby the successful event. They are allconvinced: Next year, there may notbe a World Cup, but there will beanother KHS Championship.

At the opening of the new Sinalco production operation in

Serbia (from left): Prime Minister Vojislav Kostunica, Vojin

Djordjevic, owner of the Voda Voda (SI&SI) mineral water

plant, and Maternus Gemmel, Chief Sales Officer of KHS AG.

SINALCO SERBIA: THE PRIME MINISTERATTENDS THE OPENING

SINALCO TASTES GREAT ...

Five months after announcement of a joint venturebetween the SI&SI Group in Serbia and the German com-pany Sinalco International, Sinalco Serbia opened itsdoors at the end of May 2006. The opening celebrationof production operation in the Valjevo region (locatednext door to the SI&SI subsidiary Voda Voda, see page34) was attended by anybody with a rank: ministers,dignitaries, representatives of the German Embassy –and the Serbian Prime Minister Vojislav Kostunica, whoin his entire political career had previously taken partin only five such ceremonies. KHS was also represented,by board of management member Maternus Gemmelamong others. To the great satisfaction of the numer-ous inhabitants (and employees) who appeared fromfar and near, after the official opening by the PrimeMinister there was the possibility of viewing both plantsand the modern machinery.

U.S. MARKET FOR WATER COOLERSCOOL PLUS

The market for water coolers in the United States is cur-rently growing particularly quickly. Within twelve months(until July 2006), water coolers have grown 12 percentto 500,000 units, according to Zenith International. Ofthose, 98 percent of all installations were in businesses.Zenith is assuming continued double-digit growth untilthe year 2009.

BALTIKA NEW PET TREND: GLASS

Baltika Brewery, market leader in the Russian beer market,together with PET Engineering from Italy, is starting a newPET project: beer in PET bottles that look just as nice as beerin glass bottles. The ‘Baltika3’ quality PET bottle is designedto resemble the glass bottle shape, and also has the ele-gance of glass. It was also possible to improve the barrierproperties.

HEINEKENSUCCESS RIGHT DOWN THE LINE

Heineken celebrated great success in the first half of 2006. Viewing each organ-ically, sales rose by 6.3 percent to 5,738 million euros, net profit grew by 13.7percent to 410 million euros, and EBIT (earnings before interest and taxes)grew by 10.4 percent to 726 million euros. At the same time, beer sales by vol-ume climbed 11.6 percent (6.6 percent from an organic perspective) to 62.8million hectoliters.



CONSUMER POLLRUSSIA: JUICE FOR THE ELITE

The Lewada Zentr marketing research center has investigatedthe Russian market for juices in detail. The institute polled atotal of 1800 people from 128 cities and 46 regions of the coun-try regarding their consumer preferences. An important inter-mediate result: 60 percent prefer 100-percent juices. Whethera lot of juice is on the shopping list depends strongly on income.Under a wage of 4,000 rubles per month (100 rubles are about3 euros) about 50 percent purchase juice products. At over12,000 rubles, 90 percent buy juices, nectars, fruit wines, orfruit beverages. The most active purchasers, by the way, areaged between 18 and 39 years.

WELLNESS DRINKS (I)WORLD PREMIERE: THE BEER FROM YOUR PHARMACY

Karla is the first beer-based wellness drink in the world to be sold in pharmacies. Afterinitial successes in the Saarland test market, this exclusive drink is now conquering theGerman market step by step. The Karlsberg Brewery and Amapharm have agreed to coop-erate in marketing Karla. Until now, this company has specialized in the development andsales of nutritional supplements in fruit gummy form. Amapharm has both excellent nationaland international know-how in pharmacy marketing. No wonder that now more than 800pharmacies are interested in the innovative products Karla balance and Karla well-be.“Every day there are more pharmacies wanting to offer Karla,” explains Andreas Kaufmann,Strategic Project Manager of the Karlsberg Brewery. Over the border, too, there is alreadygreat interest in Karla, Made in Saarland: Requests from the U.K., the U.S., and Japan arewhetting the partners’ interest for international distribution.

WELLNESS DRINKS (II)BOTTLES COMPOST WITHOUT RESIDUE

The pharmacy market chain Ihr Platz, represented by 728 locations through-out Germany, with a company tradition reaching back to 1895, is expand-ing its offering of organic and wellness drinks with a global first, accord-ing to company announcements. The company will carry Vitamore brandwellness drinks throughout Germany in the future packaged in fully com-postable bottles. These are a special new development for Ihr Platz andconsist entirely of polylactid (PLA). In contrast to PET, PLA is not madeof petroleum but from corn, that is, a renewable raw material. The bot-tle cap is also made of a corn-based plastic. The PLA bottles are no dif-ferent in appearance from traditional plastic bottles. In addition, saysIhr Platz, they are just as stable and can be stored nearly indefinitely.

RECORD OF SUCCESSGEROLSTEINER: BOOM YEAR 2006

Gerolsteiner Brunnen – the leading company in the German mineralwater industry – has recorded sales of 123.3 million euros in the firstseven months of 2006. That’s a gain of 6.6 percent versus the previ-ous year. Turnover increased by 3.7 percent to 4.2 million hectoliters.The particularly successful products continued to be Gerolsteiner Fit(up 210 percent), on the market since April of 2005, and the Gerol-steiner apple spritzer. According to market research institute AC Nielsen,the latter had the strongest growth, with an increase in value of 25.7percent. The deciding share of the overall success were the latest inproduct innovations, Gerolsteiner Naturell plus Frucht, and GerolsteinerMoment (both introduced to the market in May of 2006), along withGerolsteiner Sport (on the market since June of 2006).


With the slogan ‘Open House at KHS’, the KHS Grouppresented itself to employees and their families at itsvarious locations in Germany. As a global leader in tech-nology for filling and packaging for the beverage, food,

and nonfood industries, the company is very purposelymaking itself transparent to the public, presenting itselfand its qualified employees, and introducing its prod-ucts and services. For the specialists at KHS, a perfectopportunity to share their success with the community. The event series started in July at the KHS Bad Kreuz-nach plant and ended in October in Hamburg. And withextremely positive resonance: Visitors had the latest infilling and packaging technology explained, and wereastonished by high-tech production systems and researchfacilities. KHS hands-on for the whole family.

HEALTHBEER SUPPRESSES INFECTION

Once again, science has provided evidence showing that moderate beerconsumption is beneficial to health. Researchers at the Medical Univer-sity of Innsbruck demonstrated that some ingredients in beer have aninfection-suppressing effect. More precisely: Beer extracts prevent bio-chemical processes, which release interferon gamma – one of the mostsignificant messengers for inflammatory response. According to theresearcher’s discoveries, the metabolic processes positively influencedby beer extracts are closely related to the origins of chronic disease –such as coronary illnesses.

BEER NEWS BECK’S PRODUCT ON THE OFFENSIVE

After the thoroughly successful innovations Beck’s Gold andBeck’s Green Lemon, Beck’s is bringing more interestingbeer novelties to the German market. Beck’s Level 7 is anew refreshing energy mix with Guarana and an increasedcaffeine content. Beck’s Chilled Orange offers the specialtaste of kumquat, the winter orange, and a fruity-fresharoma accompanied by pleasant sweetness. Both productshave an alcohol content of 2.5 percent and are sold in trans-parent clear glass bottles.

OPEN HOUSE

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WELCOMETO KHS



FOSTER’S ACQUIREDSABMILLER INVESTS IN INDIA

SABMiller has acquired the bastion of Fos-ter’s in India for 120 million U.S. dollars.The number two company in the Indian brew-ery market intends to continue to push thesuccess of Foster’s Lager and to expand thebrewery in the Indian state of Maharashtra(currently 350,000 hectoliters). Until now,India has been the largest international mar-ket for Foster’s outside Australia.

FIRST WOMAN CEO AFTER 253 YEARSWARSTEINER FAMILY TRADITION

Chatharina Cramer, daughter of the owner of WarsteinerBrewery, Albert Cramer, is continuing family traditionas the ninth generation, having taken the reins asmanaging partner and owner in the company group(Das einzig Wahre) comprised of 112 companies. The28-year-old is the first woman heading the enter-prise in the 253-year history of the brewery group.

COCA-COLA SABCO AND KHS SIGN MEMORANDUM OF UNDERSTANDING

ONE STOP. ONE SHOP.

In June of 2006, Coca-Cola SABCO, Port Elizabeth, South Africa, and KHS signed a mutualagreement (a memorandum of understanding), which includes a close cooperation of thetwo company groups in the design of filling systems. With the highest in best-practicestandards, standardized filling technology should meet the requirements of CCSABCO inthe medium and long term around the world, guaranteeing optimum shareholder returnon investment. CCSABCO is active in seven African and five Asian countries, employs morethan 9,500 people, bottles beverages at 26 bottling plants, and supplies about 240 mil-lion consumers through 450,000 trading partners. The company’s vision: “We will be thebest Coca-Cola bottler in the world.” The festive signing ceremony of the memorandum ofunderstanding was attended by (left to right): the signatories Martin Jansen, CEO of theCCSABCO Group and Valentin Reisgen, CEO of KHS AG (seated), along with Maternus Gem-mel, Chief Sales Officer of KHS AG, Martin Schürmann, Business Manager of KHS South-ern Africa, and Erhard Magin, Director of Africa, Middle East, and Southern Europe SalesRegion, KHS AG (standing).

GLOBAL GROWTH INMILK PRODUCTION

MILK MAKES IT

Global milk production has grown notice-ably in the past few years: From 384.8 mil-lion tons in 2001 to 414.9 million tons in2005. Experts predict an additional growthof 2.7 percent in 2006. The largest milk pro-ducer is still the EU, with 132.3 million tons(2005). In second place is the U.S.A. (about82.6 million tons in 2006) and India is inthird place (about 39.5 million tons in 2006).Growth country number one in milk pro-duction is China. The Middle Kingdomincreased production in 2006 by an esti-mated 20 percent – with a production vol-ume of 33.8 million tons. That’s fourthplace, right after India.


KHS has been represented in world markets by its engineering and the proficiency of its employeesfor almost 140 years. The company stands for absolute customer-orientation, the problem-solvingcompetence of its high-tech experts, and the know-how of a consulting staff that contributesexpertise on economic issues. As proven by the team from KHS day after day.

KHS Around the Globe

CUSTOMERS, KNOW-HOW, AND CONTACTS

KHS is a partner in demand in China due to its high product qual-ity, its excellent, customer-oriented service, and maximum flexi-bility, throughout a variety of industries in this booming country –and will continue to expand its activities there in the future (seepage 4).

For instance, Anheuser-Busch Brewery in Wuhan has already– like most Chinese breweries – decided on KHS filling technology.From 2007 on, the company will be filling its globally renownedbeer using an Innofill DPG-ZMS 96/18 CC.

Pepsi-Cola International continues to rely on KHS tech-nology and service. Another installation, this one for Pepsi-Cola’soperation in Harbin, was just ordered by the company. The outputcapacity of this filling system will be 36,000 600-milliliter bottlesper hour. However, the plant is also designed for the processing of1.25-liter and 2-liter bottles. KHS is delivering an Innoclean EM 72rinser, blocked with an Innofill DRV 108/18 volumetric filler. AnInnopro CMX 36 Paramix unit will be responsible for the constantlevel of product quality. The Innopack Kisters SP 050 shrink packerwill handle the task of packaging the filled products.

Ting Hsin International Group is one of the leading companies inChina for food and beverages. The group has now ordered a turnkeyACF line for their operation in Tianjin, based on state-of-the-artKHS technology (dry sterilization). The ACF system is designed fora capacity of 48,000 500-milliliter PET bottles per hour and will gointo production in the first half of 2007.

Union Brewery Group in Beijing is innovating with the firstPET bottle beer filling facilities in China. The group specializes inthe production of beer, samshu, wine, and other alcoholic prod-ucts, producing around four million hectoliters of beer annually.

For its brewery in Beijing, the company has now ordered aPET line for beer from KHS. The line has an output of 20,000 440-milliliter or 9,000 1,750-milliliter bottles per hour. Before filling,the system rinses all bottles with water (Innoclean EM 40) and thenfills them volumetrically (Innofill DVF 60/10 SC). Due to the KHS’extensive expertise in the field of PET filling, the brewery foundthe decision for KHS leading-edge technology very easy.

Yanjing Brewery in Beijing is experiencing a strong surgein demand in the Chinese keg market. For one of the largest brew-ery groups in the country, that’s a significant segment. KHS deliv-ered and installed a complete keg washing and racking line for120 (30-liter) kegs per hour. The system is equipped with anInnokeg Till TRANSOMAT 5/1 Duo, TRANSOMAT 5/1 Mono, exteriorwasher, keg turner, and a KHS Innopro flash pasteurizer.

After the Yunnan Lancang River Group in Yunxian was suc-cessful with a KHS ACF filling line for green tea, there was no ques-tion about using KHS filling technology for the new brewery as well.At the end of this year, KHS is installing an Innofill DMG-SVF 84/12CC along with the complete process technology including a CIP sys-tem and flash pasteurizer.

CHINA: ANHEUSER-BUSCH / YANJING / YUNNAN LANCANG / TING HSIN / PEPSI-COLA / UNION BREWERY

KHS IS A PARTNER IN THE MIDDLE KINGDOM


people+markets ° news

BREWERIES SUPPLY INTERNATIONAL (BSI), ST. PETERSBURG

LARGEST KHS PET FILLER

World’s largest KHS filler for plastic bottles ever man-ufactured is destined for Russia. BSI (Breweries Sup-ply International) with headquarters in St. Petersburgordered this world-record holder for BSI’s Deka brew-ery plant in Veliky Novgorod. The dimensions of this bottling giant are 8.4 meterslong, 7.3 meters wide, and 3.6 meters high, with a weightof about 30 tons. The system in Deka (36,000 2-literPET bottles per hour) fills kvas, a Russian bread drink,produced by cooking the basic ingredients water, rye,and malt. Kvas is just as much a national drink in Rus-sia as vodka, but has a very low maximum alcohol con-tent of 1.5 percent. Innovator BSI started in Deka withkvas about two years ago. The company invested in aKHS turnkey line with a capacity of 18,000 2-liter PETbottles per hour. The new KHS Innofill DRV filler is equipped with 180 fill-ing stations – and is predestined for the filling of car-bonated kvas. Magnetic-inductive flow measurementensures exact filling volumes. Overfilling is not neces-sary. That saves product. When switching to a new bot-tle size, there is no more involved than the press of abutton. Motto: maximum flexibility for all eventualities.

KENYA: RIFT VALLEY BOTTLERS /COASTAL BOTTLERS

REFILLABLE GLASS FOR COCA-COLA

The two Coca-Cola fillers Rift Valley Bottlersand Coastal Bottlers in Eldoret and Mombasa,Kenya, respectively, are each receiving a refill-able glass bottle line with a capacity of up to36,000 bottles per hour for 0.2-liter, 0.3-liter,and 0.5-liter bottles. At Rift Valley Bottlers,KHS is integrating the existing crate washerinto the line. Both customers have relied fordecades on quality and service ‘Made by KHS’.The new systems are also designed with thelatest in technological advances, and above allare very easy to maintain. They are also pre-pared for subsequent integration of a labeler– in case the customers would later like toswitch from ACL to paper labels.

10*11

BEAMISH & CRAWFORDFLEXIBLE KEG LINE

Beamish & Crawford, a part of the Scottish & Newcastle Group, has ordered anew keg line from KHS with a capacity of 450 kegs per hour. Filling volumes:30-, 50-, and 58-liter kegs. The complete installation includes three InnokegTill TRANSOMAT 5/1 Duo keg washing and racking systems. Special features:the ultra-modern AK6 external keg washer and the DFC filling system.

MOSCOW BREWING COMPANY MYTISCHITRANSOMAT FOR MOSCOW

Moscow Brewing Company has ordered a complete keg system (from the kegexterior washer to the CIP panel) from KHS as part of a general contract forbottling systems, specifically: an Innokeg Till TRANSOMAT 5/1 Mono with allperipherals. Output: 80 kegs per hour (30-liter and 50-liter). The line is designedso that it can be extended later to 160 kegs per hour by installing an additionalInnokeg Till TRANSOMAT 5/1 Mono.

CUAUHTÉMOC-MOCTEZUMA BREWERYI120,000-CPH CANNING LINE

The Mexican beer market is growing at an impressive rate. An investment deci-sion oriented towards the company’s future was made by the Cuauhtémoc-Moctezuma Brewery in Orizaba, Vera Cruz, when they ordered a high-speed fill-ing line from KHS for 120,000 cans per hour. That makes this line one of thegroup’s largest in the southern part of the country.


PRIMO SCHINCARIOL INDUSTRIA BIGGEST KHS FILLER IN BRAZIL

Primo Schincariol has purchased the biggest filling line ever sold byKHS Brazil. The heart of the line is an Innofill DRS-ZMS with 192 valvesand a capacity of 62,000 600-ml bottles per hour. The system operateswith electronic/mechanical filling in which electrodes in each fillingvalve control exact filling levels. The filling system is equipped with abiological front table, which simplifies cleaning of the table and thestars, and reduces dirt accumulation. As a company with a 12.2 percent share of the Brazilian beverage mar-ket, Schincariol is 100% Brazilian-owned, employs more than 6,000people, and has the largest industrial campus in South America. TheSchincariol Group primarily produces mineral water, beer, and car-bonated beverages.

The Einsiedler Brauhaus GmbH, a private brewery inChemnitz, has ordered a KHS bottling machine forglass bottles. Output: 40,000 0.5-liter bottles perhour. Type: DRF 96/18 KK electronic long-tube fillerthat needs no vacuum pump, has excellent oxygenpickup values, and has a biologically optimized fronttable. The Einsiedler Brauhaus, with its particularspecial beers, is one of the largest private breweriesin the new federal states, and is relying once moreon its longtime partner KHS.

EINSIEDLER BRAUHAUS 240.000-BPH FILLER FOR CHEMNITZ

OY HARTWALL, FINLAND (SCOTTISH & NEWCASTLE)NEW: SPECIAL DOLLY PROCESSING

Finland’s leading brewery, Oy Hartwall, has ordered a KHS pal-letizing center from KHS for a 52,000-cph canning facility in itsLathi plant in the south of the country. The company, a part ofthe British group Scottish & Newcastle, will use it to processmultipacks, film-wrapped trays, and wrap-around cartons, whichwill in turn be placed on U-board trays. The innovation: 1/1,1/2, or 1/4 Europallets and dollies with 600 x 400-millimeterdimensions can alternatively be used as packaging aids and car-rier systems. KHS experts have developed a special palletizingsolution for the first time for this purpose, along with a newconveyor system, which conveys either dollies or traditionalpallets. The simultaneous processing of different packagingforms and materials is completely new.

FELDSCHLÖSSCHEN (CARLSBERG DEUTSCHLAND)TRAY PACKER FOR NON-REFILLABLE PET

The Feldschlößchen Brewery in Brunswick, Germany, a sub-sidiary of Carlsberg Deutschland, is taking delivery of anInnopack Kisters TP 50 B tray packer for 0.5-liter non-refill-able PET bottles on 18-bottle or 24-bottle trays, including apack conveying connection through a vertical diverter to theexisting filling system.

KARLSBERG BRAUEREI60,000-BPH REFILLABLE GLASSLINE GOES TO HOMBURG

A complete refillable glass line – from the decrater,bottle washer, and filling machine to the crater– was ordered by Karlsberg Brewery Homburg/Saar.The company is a traditional beer brewer, verysuccessful with its Mixery brand beer mixed drinks,and is promoting canned beer exports, to Franceand other countries. KHS had previously receivedan order from Karlsberg for a new pasteurizer –the existing two-year-old pasteurizer will now berelocated elsewhere. The new line (with a capac-ity of 60,000 0.5-liter bottles per hour) was par-ticularly compelling due to its consumption fig-ures and the technological data for the filling,capping, and bottle washing machines. For theprocessing of a variety of formats, the packingmachines are equipped with automatic formatchanging systems.

HGL – HACKLBERGER GETRÄNKE- UND LOGISTIKCENTERINVESTMENT IN THE FUTURE

The HGL-Hacklberger Getränke- und Logistikcenter GmbH in Hutthurm,Bavaria (parent company: Brauerei Hacklberg Passau) is investing exten-sively in new equipment for its central logistics location including * KHS Innoclean EE 27/95 bottle washer with an infeed conveyor,* KHS Innofill DRS/ZMS 108/18KK/18SV bottle filling and cap-

ping machine, * KHS Innopro Paramix CMX 18-6/T20 blending system with aconnection for beer. The owner of Brauerei Hacklberg for many years has been BischöflicheKlerikalseminarstiftung St. Stephan of Passau. It is the largest brew-ery in the eastern Bavarian region with a full range of products.



DAESUN DISTILLINGHIGH PERFORMANCE FOR SOJU IN KOREA

Daesun Distilling in Busan, South Korea, is experiencing enormous growth rates,and is therefore systematically expanding its production capacities with a com-pletely new filling plant. In the future, several high-performance systems forthe bottling of Soju should meet the demand for the local market. Daesun Dis-tilling has just selected KHS for its first filling line. It has a capacity of 66,000bottles per hour – making it the first system to top the 60,000-bph mark inKorea – and goes into production in April of 2007.

ASAHI BREWERIESTOP PASTEURIZER FOR JAPAN

Asahi Breweries Ltd. in Ibaragi, Japan has ordered a new high-per-formance pasteurizer from KHS that processes 1200 cans per minute.KHS was able to fulfill the increased performance requirements atAsahi Breweries. For the first time, a KHS pasteurizer is going toJapan with dynamic pushover on the infeed and outfeed ends, alongwith PLC control. As particularly compelling, the customers foundthe strict compliance of the specified PUs, the fully automatic pas-teurizer operation, and the type of controls normally used in Japan.

TROY AQUACOMPLETE REFILLABLE PET TIMES TWO

The latest KHS Innofill filling technology will soon be onthe job at Troy Aqua in Sittensen, an idyllic little town locatedbetween Hamburg and Bremen. The renowned specialist inthe filling of generic brands has just ordered two completenon-refillable PET installations from KHS, each with a capac-ity of 26,000 1.5-liter bottles per hour. The ultra-modernlines are connected to the tried and tested Innopro Paramix,apply labels using Innoket high-tech hotmelt sheet-feedand roll-feed equipment. The KHS Innopack Kisters SP andCSM particularly stand out in the dry area along with a KHSInnopal PB palletizer. Both lines are monitored by KHSInnocheck inspection units. Troy Aqua has two newly drilledmineral water wells at its Sittensen location, has purchaseda modern production plant located on a 40,000-square-meter piece of property, and operates three shifts aroundthe clock to meet the high market demand.

KIRIN BREWERYANNIVERSARY: 25TH CONTIKEG FOR KIRIN

The most of continuously rotating keg machines in the world (CONTIKEG)are installed in Japan – the majority of which at the Kirin BreweryCompany Ltd. The two recently ordered machines now up the count to25. KHS is delivering an Innokeg Till CONTIKEG washer 32/30 and aCONTIKEG racker 20/18 with an output capacity of 1100 kegs per hour(7-, 15-, and 20-liter) to Kirin’s Kobe plant. For the first time, the newCONTIKEG generation is working with a Mitsubishi control system. Themachines have – as usual in Japan – earthquake-proof cup-shapedfeet. The washer is equipped with an automatic acid program to decal-cify the cleaning heads (descaling). The filler has quick-changeovervalves that shorten product changeover enormously, reducing prod-uct losses (product changeover without CIP caps). The filler is resist-ant to the rather aggressive cleaning and disinfecting agents used forfoam application (external cleaning and disinfecting). Naturally, theoutstanding DFC filling system is used in this filler as well. The two rotary keg washing and racking machines, which meet Kirin’sexpectations in the latest of technological advances, will go into pro-duction in April of 2007 after only four weeks of installation and com-missioning. Even in the late 1980s, Kirin was one of the first companies to rely oncontinuously rotating keg machines.

COCA-COLA ARCA GROUP45,000-BPH REFILLABLE PET LINE

The second largest franchise bottling plant for Coca-Cola in Mexico, Coca-Cola ARCA Group in Hermosillo, Sonora, has ordered an innovative turnkeyfilling line for 45,000 600-ml non-refillable PET bottles per hour. The newvolumetric PET filler has no front table, has a pipe ring bowl, operates withservo motors, and is equipped with a system that automatically inserts andretracts CIP caps.


Standards Benefit the Customer

KHS renewal concept 2010plus

KHS-JOURNAL: KHS has announced that it will carryout even further product standardization as part of thechange process. Where do you see advantages for thecustomer here?VOLKER TILL: Standardization will result in extensiveunification. All standard – or to put it another way – iden-tical products only have to be explained once, not only tothe customer but also to our staff and service engineers.This way, we will be considerably faster and more efficientin the training of our globally active employees. Conse-quently, we are also able to provide better service. At the

same time, we are able to manufacture our products atwidely differing locations based on identical drawings.This saves shipping costs and – what is often more impor-tant – time, for in the case of sea freight, we are not talk-ing in terms of days but of weeks.

KHS-JOURNAL: What do you consider to be the mostimportant aspects of product standardization at KHS?VOLKER TILL: The experience gained is further enhancedin tried-and-tested products. The same assemblies andparts enable us to produce faster and also more cost-effec-

Interview with Volker Till, KHS’ Chief Technical Officer


14*15KHS 2010plus °

tively. Our global alliance, an important strength of KHS,will benefit most from this. This will bring KHS even closerto its customers.

KHS-JOURNAL: Will the standardization of controltechnology among other things play a decisive role?VOLKER TILL: The standardization of control engineer-ing has always played an important role in the past. Stan-dardization is basically also compliance with norms. DINand ISO have long been extensively used in mechanicalengineering. But standardization, particularly in the soft-ware area, is still in its infancy. Here, in many cases, indi-vidual engineering is still the order of the day. KHS isalready making global standards for control and regula-tion technology available on the World Wide Web throughthe Engineering Portal. This service will be continuouslyexpanded.

KHS-JOURNAL: To what extent has product standardi-zation already progressed? Do you have any idea whenthis might be complete or is it a permanently ongoingprocess?VOLKER TILL: Our products are modified to suit con-tinuously changing requirements at appropriate intervals.This is a necessity in our branch of industry. From this,you can say that it is a never-ending story, in the positivesense, of course.

KHS-JOURNAL: As a turnkey supplier to the beverage,food, and nonfood sectors, KHS provides both packagingas well as filling equipment. Do different aspects apply inthese areas with regard to product standardization?VOLKER TILL: The closer we get to the end of the pro-duction line, the more we find standardized processes andtechnologies. Virtually all products are palletized. Beforethis, most products are either packed in boxes or wrappedin film. Prior to these processes however, the majority ofproducts are labeled, which shows that these productionprocesses form the core technology of KHS. Now, the closer

we come to the product itself, the more individual thetechnical solutions become. But standardization is alsopossible here. The best example is the turnkey lines wesupplied to a well-known U.S. customer who fills liquidsoap in PET containers using ‘standard beverage fillers’from KHS that required only a few very slight modifica-tions to suit the field of application. The end packagingin this case is the usual KHS standard.

KHS-JOURNAL: What about the consideration of indi-vidual customer requirements with KHS equipment in thefuture? Will it still then be possible to obtain system con-cepts that are exactly tailored to the respective company?VOLKER TILL: Naturally, standard cannot mean that wewill offer only one type of filling valve. Standardizationmeans arranging processes and technologies so that manyrequirements can be fulfilled with just a few different solu-tions. Furthermore, this is a significant advantage ver-sus an individual solution that is manufactured only once.We can call upon proven technology. Prototypes and therelated drawbacks for the customer testing them willbecome a thing of the past. Take the automobile indus-try as an example. In spite of standardization, no two carswill be the same on the assembly lines within the next twoyears. In exactly the same way, KHS customers will alsoreceive machines and systems optimally tailored to theirrequirements as part of standardization.

KHS-JOURNAL: Will the customary KHS quality also beguaranteed to the full extent in the future? VOLKER TILL: Standardization enables us to make bet-ter use of past experience and produce larger quantities.Parts, processes and also the people involved in addingvalue benefit from this. Everything is easier to under-stand and can be continuously improved due to the ongo-ing pedagogical benefits. What it boils down to is thatstandardization quite clearly improves quality.

Mr. Till, thank you very much for this interview.

“Our global alliance, an important strength of KHS, will benefit most from this.”


Famous for Nuremberg Bratwurst, Nuremberg Lebkuchen, the Nurem-berg Christmas market and popular attractions such as Albrecht Dürer’sHouse, the Gänsemännchenbrunnen [Goose Man Fountain], the Hand-werkerhof [Tradesmen’s Court] and much more, the town of Nurem-berg has something that other towns do not: that certain extra ofcoziness and an atmosphere of well-being. It remains to be seenwhether the ‘Nuremberg town feel’ radiates to the Nuremberg TradeFair and thus the BRAU Beviale, the industrial gathering per se, orwhether it is the unique exhibition concept, which has been thoughtout down to the last detail, that attracts the German and Europeanbeverage sector every year in November. Perhaps it is just the com-bination of these factors. For one thing is clear: BRAU Beviale hasnot only established itself as one of the leading European trade fairsfor the beverage sector, but, at the same time, has become a ‘familygathering’ of the European beverage industry. BRAU Beviale is allabout getting together. Bernd A. Diederichs, Managing Director ofNürnbergMesse, sees the BRAU Beviale fair as a “European trade fes-tival with heart.” KHS journal in conversation with Bernd A. Diederichs,the man who actually wanted to become an architect and who nowproduces, establishes and – what is certainly a significant factor –manages and sustains successful exhibition concepts.

KHS-JOURNAL: ‘Back to the roots’ is a much-quoted saying, which is today treated as a guarantee for success in numerous companies. This saying appears to have been used repeatedly with regard to BRAU Beviale over the decades. Is a continuous ‘return to the roots’ of the exhibition the real recipe for success?

BERND A. DIEDERICHS: In fact, it is very important never to losesight of the roots of an exhibition. Such a strategy is often looked uponas being too traditional. In my opinion, a return to the roots and atthe same time an establishment of innovative ideas thoroughly harmo-nize with one another. The BRAU exhibition established in Nurembergin 1977 has thus changed from a national exhibition to a Europeantrade fair, its name and activities have been expanded without renounc-ing its ‘BRAU roots’, and in spite of this has remained a ‘family gath-ering’. Instead of a ‘small national family’, it is today a ‘large Euro-pean family’, and instead of a meeting of brewers, today it is a gath-ering of the whole beverage industry.

° Where in your opinion do the specific advantages of a ‘familygathering’ lie for exhibitors and visitors

* Primarily in informal communication. People know each other;they meet, and look forward to seeing each other again. And then thecommunication between exhibitors and visitors and among the visi-tors themselves takes place automatically. Many visitors to BRAUBeviale feel that they have missed something if they do not attend theexhibition – which, according to our exhibition surveys, can also havea negative effect on business. We therefore see an exceptionally con-stant frequency of visitors. This, in turn, is to the benefit of theexhibitors. Of course, as well as the ‘family gathering’ aspect, we also see the suc-cess of BRAU Beviale in a high orientation towards innovation. Thething is to accommodate movements in the industry and to presentinnovations in the respective sectors. As an exhibition company, weuse appropriate accompanying events to take into account the inno-vative character.

European ‘Family (Af)Fair’ Interview with Bernd A. Diederichs, Managing Director of NürnbergMesse, held prior to the trade fair

From a National to a Getting together at BRAU Beviale


2006 (1477 exhibitors in 2004). On the other hand, companies arenaturally sending fewer employees to trade fairs than has previouslybeen the case. The decisive factor is, however, that these companyrepresentatives generally have a very significant order budget. I pre-dict that the number of trade visitors to BRAU Beviale 2006 will remainat about 37,000. Expertise and decision-making powers are increas-ing. Incidentally, 88 percent of all trade visitors to BRAU Beviale in2004 were involved in purchasing and procurement decisions for theircompanies.

° Away from the number of visitors and exhibitors to the all-impor-tant factor – visitor and exhibitor satisfaction.

* Of course, we carry out regular surveys in this area. In 2004, wereceived a clear ‘Yes’ from 99 percent of visitors to the question ofwhether they were satisfied with the information and the contactopportunities at the exhibition booths. This is a figure that cannot betopped, and at same time is the highest level of satisfaction ever achievedat all NürnbergMesse events. The overall exhibitor satisfaction at the

° An exceptionally constant frequency of visitors can also meanthat visitors are static and that new target groups of visitors arenot really expected. What do you think of that with regard toBRAU Beviale?

* This is not at all the case. New visitors to BRAU Beviale are quicklyintegrated into the ‘family’. As indicated above all when BRAU Bevialechanged from a national to a European event. The internationality ofBRAU Beviale is continuously increasing. We also expect further growthin 2006. Thirty-eight percent of the exhibitors and twenty-seven per-cent of the visitors at BRAU Beviale 2004 were from abroad. The largestinternational presence was provided by Italy with 73 exhibitors aheadof Austria with 61, and the United Kingdom with 60. Substantial groupsof visitors came from Austria, Switzerland, Belgium, the Czech Repub-lic, and France as well as from the countries of the Middle East andEastern Europe. We believe that these countries in particular still havean enormous potential. For example, if you look at beer consumptionin the Middle East and Eastern Europe, growth rates of more than 47percent have been realized here since 1999. At the same time, Rus-sia, the Ukraine, and Poland represent the strongest growth markets.Of course, with all the well-meant euphoria, we are not closing oureyes to reality. Numerous mergers and company takeovers at on theGerman and European stage lead us to expect a consolidation of thenumber of exhibitors at a high level. We expect 1500 exhibitors in

After studying economic sciences, Bernd A. Diederichs

began his career in the German trade fair industry.

The fact that this industry appealed to Diederichs is

reflected in 30 years of professional experience. His

first professional stations were Hanover and Düssel-

dorf, where Diederichs worked for national and international trade fair organizers. At Deutsche Messe AG in Hanover, Bernd

Diederichs assumed a leading role in the development of new exhibition themes. As Divisional Manager for Consumer Goods

Exhibitions at the Messe Frankfurt, the name Diederichs is closely linked with the development of the world’s leading trade fairs

for consumer goods such as Premiere and Ambiente. Since 1997, Bernd Diederichs has been managing the NürnbergMesse, a

company that today employs nearly 240 people and is one of the 15 largest exhibition sites in the world. The turnover of Nürn-

bergMesse has almost tripled since 1997 to an expected 120 million euros in the 2006 financial year.

16*17dialog+opinion °

“People know each other and look forward to seeing each other again.”


during the period of the exhibition. This way, we do not distract thevisitors from the actual objective of the exhibition, the making anddevelopment of contacts, any more than they would like. What we visu-alize for the future, however, is an event day in advance of the exhibi-tion. We will first carefully assess the interest of exhibitors and visi-tors in this idea – fully in accordance with our philosophy.

° BRAU Beviale has slowly but surely developed from a nationalto a European exhibition and has likewise slowly but surely ex-panded the target group of visitors from the brewing industryinclude the entire beverage sector. Will BRAU Beviale ‘expand’further in the future with regard to the catchment area and target group? What are the goals in this regard?

* When I am asked this question, I like to reply with a quotationfrom the man in the street, which says: ‘A cobbler should stick to hislast’. The deliberate self-imposed restriction with regard to the tar-get group is a very important factor for us of every top-class trade fairthat is tailored towards specialists. By just this means, we produce anunbelievably high contact density and efficiency for which BRAU Bevialeis also famous. This means that the subject areas of beverages andliquid food will always remain our core areas. As far as exhibitors andvisitors are concerned, we will continue to focus on the German andEuropean market. However, by agreement with the exhibitors, we willalso address their extended customer target groups and are thereforeplanning additional activities in the near East, for example. Our gen-eral principle is that, as NürnbergMesse, we orientate ourselves con-sistently toward the interests of the exhibitor. We are certainly notgoing our own way here.

last BRAU Beviale was 92 percent. We see this as a clear confirmationof the exhibition philosophy. But this does not prevent us from set-ting ourselves a target of nearly 100 percent in this area.

° Do you see a connection between high exhibitor and visitor satis-faction and specific event planning by NürnbergMesse duringBRAU Beviale? What accompanying events are you planning inthe exhibition company in 2006?

* Exhibitor information relating to innovations is one and, in ouropinion, a particularly important side of the coin. The other side, ofcourse, is accompanying events, which must be exactly aligned withthe industry requirements. In the Logistics Solutions Center, a special exhibition, exhibitors willbe presenting innovative products and services for optimizing the logis-tics chain from the supplier to the point of sale at exhibition booths,in trade presentations, and forums. This will include route planning,fleet management, warehouse management, batch tracking, and, ofcourse, RFID. The award of the European Beer Star on the second day of the exhibi-tion is thematically well-suited to BRAU Beviale. The private breweriesof Bavaria, the ideal supporting organization for the exhibition, havecreated this beer prize together with their European umbrella organi-zation, the Association of Small and Independent Breweries. The objec-tive was and is to advertise the wide variety of European beers. Thisyear, the intention is to exceed the participation record of 400 beersfrom 23 nations. Since we have intentionally limited BRAU Beviale to three days in theinterest of exhibitors and visitors, we do not promote any other events

“drinktec and BRAU Beviale complement one another so well that they can basically belooked upon as an overall industry concept.”


° What about the duration of the BRAU Beviale exhibition and thebooth restrictions? Is NürnbergMesse acting in the interests ofthe exhibitors?

* The answer to this is clearly yes. The three-day duration of theexhibition is completely in line with the exhibitors’ expectations. Themajority of exhibitors see a clear efficiency advantage simply becauseof the incredible concentration of the exhibition period. If this situ-ation should change, then we are naturally prepared to respond. Forin everything that we do on the part of the exhibition company, thefocus is very clearly on our customers – the exhibitors. We are doingthe right thing only when we are satisfying our customers’ wishes.And, in my opinion, the BRAU Beviale exhibition and NürnbergMessecan only continue as successful brands with this approach. The same applies to the booth restrictions. This is also oriented towardsthe exhibitors’ requirements. Limited booths means limited expense.Cost limitation of this kind has been implemented with great benefitfor three years in a row. This also enables medium-sized companies,with which BRAU Beviale has grown up, to participate in the exhibi-tion. In combination with drinktec, which takes place every four years,this is an ideal integration from an economic point of view.

° You mentioned the BRAU Beviale and NürnbergMesse brands. Doyou consider specific brand policy to be an important factor?

* In the case of consumer brands, we talk intensively about brand for-mation. I think brand formation is also important for exhibitions. Werespond accordingly with advertising campaigns, press work, specificvisitor marketing, and a high level of attention with regard to our image.

° Apropos drinktec: In this regard, do you see the successful addi-tion of an international event to the European-oriented BRAUBeviale?

* In my opinion, drinktec and BRAU Beviale complement one anotherso well that they can basically be looked upon as an overall industryconcept.

° Anyone who has followed the interview this far will know why heor she should attend BRAU Beviale from November 15 to 17. Whatis the situation regarding hotel accommodations? Will thosedeciding to go on short notice still be able to find a room?

* Nuremberg has an allotment of about 25,000 hotel beds. With37,000 visitors to BRAU Beviale and 1500 exhibiting companies, hotelaccommodations in and around the city could be scarce. Of course,we provide a room service from BRAU Beviale and will attempt to findthe right accommodations for visitors at all times. If this is not suc-cessful within Nuremberg itself, I can recommend the surrounding areaof Franconia, which has also shown itself to be extremely welcomingto guests. Here, for instance, you will find comfortable and charm-ing brewery inns, which are easily accessible for those arriving by car.And here too, the much-lauded ‘family character’ of BRAU Beviale canbe lived and experienced every day before and after visiting the exhi-bition just as in the city of Nuremberg.

° Mr. Diederichs, thank you very much for this interview.

18*19dialog+opinion ° Getting together at BRAU Beviale

“The intentionally self-imposed restriction with regard to the the definition ofthe target group is a very important factor for us of every top-class tradefair that is tailored towards specialists.”


THE FRUIT KING

In Serbia-Montenegro, the beverage market is growing at breathtaking rates.Fruvita has built a strong market position in nectars, fruit juices, and fruitjuice beverages. The company is considered a pioneer in the use of leadingACF technologies – Made by KHS.

Fruvita in Serbia relies successfully on ACF with dry sterilization


Goran Redzic is a textbook businessman:Where other people see nothing, he findsmarket gaps and builds businesses. Redzicnoticed a few years ago that among otherthings there was not a particularly greatvariety of fruit beverages being offered inSerbian market. He decided to change that

by beginning production of fruit nectars andlaunching Fruvita in 2003.

In the f irst year, he had sales of700,000 euros, and invested the same amountin marketing and advertising for his newbeverage brand Hello.

Success, as Redzic knows, can onlybe achieved in the long term with quality.He was already living according to this prin-ciple, when he founded an advertising jour-nal for the Serbian market, which is stillhighly regarded today. For this reason,Redzic also relies on quality and the latestfilling technology in his new beverage oper-ation. This is also why the innovative KHSACF technology (Aseptic Cold Filling) withthe dry sterilization process is implementedat Fruvita. This allows Fruvita to eliminatepreservatives completely in its fruit juicebeverages.

REDZIC RULE 1:

ENSURE CONSISTENT QUALITY

The success of the consistent quality strat-egy is obvious: Today, Fruvita, with a mar-ket share of 25%, is number two among Ser-bian producers of fruit beverages, and isconsidered a pioneer when it comes to tech-nical equipment.

In 2004 – one year after it was founded– the company’s yearly sales were already

4.5 million euros. In the same year, Redzicexpanded his product range of ten nectarsby adding five other fruit juice beverages.Redzic thus became the first Serbian providerof fruit juice beverages on the domestic mar-ket. Last year, sales more than tripled, to15.2 million euros. The goal for 2006: a100% increase in sales.

REDZIC RULE 2:

ENCOURAGE INNOVATION

Since 2005, Fruvita is offering not just fruitjuice beverages and nectars, but fruit juicesas well. Their largest sellers, however, arestill the fruit juice beverages, with a 70%share of sales. Incidentally, the most pop-ular style is multivitamin.

Fruit juice and nectar are packagedin drink cartons, while the fruit juice bev-erages are bottled in 0.5 and 1.5-liter PETbottles. “In my opinion, this is exactly theright style of packaging for a new and cor-respondingly modern drink on the Serbianmarket,” says Goran Redzic.

REDZIC RULE 3:

UTILIZE TECHNOLOGICAL ADVANTAGES

Their investment in KHS ACF system tech-nology makes Fruvita one of the pioneers ofACF, not just in Serbia but also around theworld. Redzic really didn’t want to play the

THE TASK Installation

of an ACF system

• in very limited amount of space,

which

• fulfills the strictest of hygienic

requirements.

THE SOLUTION A KHS ACF line

• in an L-shaped layout, which

• uses clean room technology with

mini-isolators.

2

1

* Specialist in fruit-containing drinks

* Market share in Serbia 25 percent

* Sales2003: 0.7 million euros2004: 4.5 million euros2005: 15.2 million euros

* Use of cutting-edge ACF Technology

THUMBNAIL PORTRAIT: FRUVITA2

Filling process in the ACF block: volumetric using electromagnetic inductive flow metering.

20*21task+solution °


in the capper. The filling valves themselvesas well as all moveable parts, drives, andcontrols are located outside the sterile cleanroom. Parts and assemblies, which carry orgenerate contaminants have no contactwith the sterile zone.Sterilizer/activator area. An air con-veyor brings the non-refillable PET bottlesto the KHS ACF block. There, the bottlesfirst enter the sterilizer/activator area overan infeed plate that is free of format parts.

part of the vanguard, however: “While mak-ing our decision, we looked only at the advan-tages this technical equipment had to offerus.” KHS ACF technology will allow Fruvitato offer the consumer a natural product with-out preservatives, bottled under the strictestof microbiological safety measures. “Byusing the dry sterilization process, we ben-efit in comparison with the ACF wet processfrom extensive cost advantages with regardto the sterilization method and from thesystem’s low space requirement,” continuesthe company boss.

Fruvita asked for the L-shaped lay-out to allow optimum integration of theline into the existing building. No prob-lem for KHS. The modular concept is par-ticularly excellent in that a variety of instal-lation options is available even when spaceis limited.

The basic data of the new system:

* Capacity: 15,000 0.5-liter or 13,000 1.5-liter PET bottles per hour.

* The bottling process takes place in theso-called mini-isolator where class 100 cleanroom conditions prevail. It is comprised ofthree components, the sterilizer, the acti-vator, and the filler-capper unit. * The isolator is extremely hygienic andexceptionally space-saving. This compactisolator equipment houses only the PET bot-tle guide elements in the sterilizer and acti-vator, as well as the filling valve outlets inthe filler carousel, and the capping heads

Before startup, the system must demonstrate its reliability in the area of hygiene. Andthis is how it was done:

* For validation, Fruvita filled 10,000 PET bottles.

* They were then stored at 28°C for three weeks in a closed room. (The validationis successful if no more than a single bottle spoils.)

* At Fruvita, not a single bottle was contaminated: “We didn’t expect anything elsefrom KHS ACF equipment,” says Goran Redzic.

VALIDATION: A 100 PERCENT JOB2

Top Capped PET bottles: Coming onto the conveyor belt. Bottom

Innofill SV-ACF Capper: Separates the capping movement of the

bottles from the rotation of the cap. Right Sterilization: Steaming of

the inside and outside surfaces with H2O2.


22*23

Hydrogen peroxide (H2O2) sterilizes theplastic bottles inside and out. The hydro-gen peroxide is not only evenly distributedon the interior and exterior surfaces of thebottle when it evaporates, but also con-denses on undercuts, edges, and angles.This is a deciding factor for Fruvita espe-cially, because the modern PET bottles havenumerous indentations and to some extenta rough surface. The idea is to give the buyerthe feel of holding a fruit when picking upthe bottle.

After the hydrogen peroxide is vapor-ized, warm air is introduced to activate theactual sterilization process. During thatprocess, H2O2 breaks down into its compo-nents oxygen and water, and dries withoutleaving a residue. At Fruvita, one activatoris enough. For higher filling capacity, twoactivators are recommended.

An important factor in the fillingprocess is supplying sterile air. The com-pact isolator technology provides two HEPA(High Efficiency Particulate Air) filters inthe ceiling. They filter the air and guide it,sterilized, into the mini-isolator, with a ster-ile air flow, which moves in the directionopposing the bottle flow. The system guidesthe H2O2 and sterile air out of the cleanroom and exhausts them after the sterili-zation process is complete. From the filler,through the capper, to the bottle discharge,the sterile air moves parallel to the bottle

flow. One air lock each in the infeed andoutfeed areas ensures additional safety byusing overpressure of less than one bar toreliably prevent the entry of ambient air.Filling process. After cleaning, the PETbottles move into the filler, in which Fruvitabottles only non-carbonated fruit juicebeverages. A two-stage, open-jet fillingvalve fills the PET bottles without pressure.This valve is an all-rounder: It can fill eitherpulp-containing or thick non-carbonatedbeverages. A magnetic-inductive flow meterregulates the volumetric filling process.

A special highlight: The line is con-trolled locally by a new KHS system that con-trols the filling block fully automatically andrecords all data in real-time at each fillingvalve, monitors the filling process, and reg-ulates the production process. All parame-ters pertaining to the filler control are storedin so-called recipes for different products,

bottle sizes and shapes, and filling capaci-ties. When the system switches recipes, allthe data needed is loaded into the filler con-trol unit. The result: The cleaning and fill-ing process starts reliably – guaranteedprocess reliability at the press of a button.

The system directs the informationgathered to the KHS plant information sys-tem AIS for the monitoring of all critical sys-tem points in the aseptic area. Safety and hygiene. Maximum micro-biological safety has the top priority in theKHS ACF block. The system provides reli-able information on sanitizing and disin-fection cycles. Main sanitizing of the sys-tem is performed every 48 to 72 hours,which also includes the complete CIP andSIP cycles as well as the sterilization of themini-isolators.

In addition, the surfaces are auto-matically disinfected every four hours. If

task+solution ° Fruvita in Serbia relies successfully on ACF with dry sterilization

Dry Sterilization: Fruvita is one of the first in the world with

the latest in technical filling solutions.


Fruvita in Serbia relies successfully on ACF with dry sterilization

work is necessary inside the clean room area,a special sterile air control is able to sepa-rate individual mini-isolator areas and ster-ilize them quickly. “Everything, but absolutelyeverything, is really well controlled here.More safety would really not be possible,”summarizes Goran Redzic enthusiastically.

Behind the filling system, there isan ACF-compliant Innofill SV-ACF capper.As with bottle sterilizing, hydrogen perox-ide is also used to sterilize the caps. Thisprocess is performed in the separate capsterilization unit. Of course, even in thisstandalone machine, all the signif icantprocess parameters are monitored andlogged in AIS.

REDZIC RULE 4:

QUALIFY STAFF

Despite all the safety systems, however,any installation is only as good as its oper-ating personnel. That’s why KHS providesan extensive training program for Fruvitaemployees on topics relevant to hygiene.Praise from Redzic: “The employees involvedwith the new ACF block are now wellacquainted with hygiene measures and, atthe same time, highly motivated. SpecificKHS training courses have made a decisivecontribution to this. We are also pleasedwith the comprehensive advice provided byKHS. For example, KHS has supported usin every aspect of setting up our ultra-mod-ern laboratory.”

REDZIC RULE 5:

EXPAND SUCCESS ACCORDING TO PLAN

The success and quality of Fruvita beveragesare internationally discussed: Even beyondSerbian borders, there is a significant inter-est in high-quality Fruvita products in themeantime. The first exports went to Bosniaand Macedonia. Meanwhile, export accountsfor ten percent of total sales of fruit juice

beverages. The demand here is thereforegreater than the supply. Redzic: “We areusing KHS ACF equipment in four-shift oper-ation. That is still not enough for our cus-tomers.”

Manfred Keller, Sales Manager South-East Europe,

KHS AG, Bad Kreuznach

Andreas Flora-Asendorf, Project Manager, KHS AG,

ACF Filling Technology Competence Center, Hamburg

• WEBSITE www.fruvita.co.yu• CONTACTS

Manfred Keller, Sales Manager, South-East Europe, KHS AG, Bad KreuznachTel: +49 (671) 852-2655E-mail: [email protected] Flora-Asendorf, Project Manager, KHS AG, ACF Filling Technology Competence Center, HamburgTel: +49 (40) 63703-36139E-mail: [email protected]

INFOBOXfi

Left Fruvita’s owner Goran Redzic: Success with the production of fruit juices, nectars,

and fruit juice beverages on the Serbian market. Right KHS ACF technology: Fills 15 kinds

of fruit juice beverage at Fruvita.



The viticulture in the vicinity of the city ofKrems can be traced back at least to thethird century A.D. The heart of regionalwinegrowing beats in the valley of the Danube,at the entrance to the Wachau, the gatewayto one of the most beautiful river valleys ofEurope – and Austria’s finest vineyards.Thanks to the interplay of microclimatessupported by river currents and the valleysprotected from the north, along with per-fect soil, it is possible to produce a varietyof different types and qualities under idealconditions. So it’s no wonder that WinzerKrems, now the largest viticultural cooper-ative in the country, has its home here.

“Our standard is solely quality. Wetherefore traditionally follow innovativemethods in order to provide our customerswith the authentic natural product, Kremswine, flawless in all respects,” stresses FranzArndorfer, Chief Cellar Master of the coop-

erative. Literally all facets. Because WinzerKrems not only utilize the strictest of stan-dards in growing and in winery operations,they also market their wine off the beatenpath, thus representing a role model for theentire industry.

EXPERIENCE WINE

In August of 2005, Winzer Krems started theunique visitor experience program ‘winesense’, which celebrates wine at eight sta-tions as an experience for the senses: At thefirst station, the vineyard, there are 18 vari-eties of grape planted around the traditionalHiata – the hut of the vineyard custodian.

The second station offers a walk-on aerial photo of Krems and the surround-ing winegrowing towns. The third stop isthe old domed cellar containing a selec-tion of rare wines. There are wines here,for instance, from the 1948 vintage, guarded

The Keg Wine PioneersWinzer Krems: Austria’s largest viticultural cooperative has a tradition of innovation

‘In vino veritas’ – in wine there is truth – the friends of the grape have known this since the days of the Romans. And for the same length of time, the people of Wachau in Austria have had their loveof wine, the center of which today is the city of Krems. The largest viticultural cooperative in Austria is headquartered there.

THE TASK

Filling of wine in kegs

• without sacrificing quality,

• with perfect cleanliness.

THE SOLUTION

Innokeg Till TRANSOMAT 3/1

• with a perfect filling process

for maximum flexibility and

• the strictest of cleanliness,

using pulsed cleaning.

2

1

Left Enjoying the occasional glass of wine from the keg just like their customers: Franz Ehrenleitner,

Managing Director of Winzer Krems (right) and Franz Arndorfer, Winzer Krems’ Chief Cellar Master. Right Visiting

on foot: It’s easy walking on the aerial photograph of Krems and surrounding winegrowing towns.


Advantage I: Overall stability

The kegs are hermetically sealed, opaque,taste-neutral, resistant to corrosion andimpact, and allow nearly unlimited storagetimes without affecting the quality of thewine.

Advantage II: Long service life

Since deposits are mandatory for kegs, theyare environmentally friendly and have anextremely long service life – 30 years of useis not uncommon. Winzer Krems racks onekeg an average of four to five times a year.In all, the viticultural cooperative owns10,000 kegs, 8,000 of which are 25-literkegs, and 2,000 are 50-liter kegs.

Advantage III: Little handling effort

Restaurateurs like wine in kegs for theirsmall amount of handling. After the one-time fitting of the tap, they can tap the kegwithout additional work or maintenancesteps until it is empty. This eliminates time-consuming opening of bottles, along withthe negative affects of bottle corks on thetaste. And, wine from the keg is always atthe right dispensing temperature thanks tothe control system in the dispenser.

But Cellar Master Arndorfer knowsthat many restaurateurs are skeptical ofwine in kegs. That’s why “restaurant busi-nesses that rely on wine in kegs must betrained individually.” In Austria just as in

Keg sales of about 1 million liters, 60% of which is white wine, with three different styles ofGrüner Veltliner, and 40% red wine, with Blauer Zweigelt, Welschriesling, and Blaufränkisch.

SPOTLIGHT: KEG FILLING AT WINZER KREMS2

Left Fascinating: the illuminated fermentation and storage tanks. Center High quality of wine in kegs: Hence the use of the Innokeg Till

TRANSOMAT 3/1 from KHS. Right Gentle filling: Multiple controls ensure a perfect filling and cleaning process.

by virtual cellar ghosts. An extensive lightand music production allows them to revealold secrets and new know-how about thesestored treasures.

From the fourth station, the stylishbarrique cellar, the visitor has an impres-sive view of the cooking and storage tanks,illuminated in rich green. In the tastingroom, the guest can then also taste the wineimpressions already seen, heard, and felt –in the stylish atmosphere of the Winzer Kremsbrand. The conclusion is then in the eighthstation, the wine shop, where not only winesbut also other specialties, such as wine choco-lates, are available.

The concept is well accepted. “Inmid-2006 we greeted the 20,000th visitorto our world of wine experience. Our vine-yard sales grew by 33% compared to the pre-vious year,” Franz Ehrenleitner, ManagingDirector of Winzer Krems, says enthusiasti-cally. The wine cooperative has medium-term plans for about 40,000 visitors per yearfrom at home and abroad.

WINZER KREMS, KEG PIONEER

A total of nearly 10 million liters of WinzerKrems quality wines are produced by thecooperative each year. A particular featuresets the cooperative apart: Although thewines are delivered to end consumers andrestaurants in the industry-standard bottlesizes and shapes commonly used by otherwineries as well, Winzer Krems also deliverswine to restaurants in kegs. Truly ground-breaking.

The company started filling wine inkegs as far back as the mid-1970s. Today,kegs represent 10 percent of their overallsales while the keg share in the restaurantsales sector is 40 percent.

KEG TECHNOLOGY, COMPELLING DUE

TO ADDED VALUE

Not without reason, because keg technol-ogy offers both the cooperative and theircustomers a series of advantages. “We seeclear advantages in kegs,” confirms FranzArndorfer.


26*27

the export market of Southern Germany.The best arguments are the more than 30members of the external sales staff on site– and Kremser quality: “If the keg were notsuch a high-quality container, we would cer-tainly not trust it with our outstanding qual-ity wines,” says Managing Director Ehren-leitner, the traditional supplier of the Vien-nese Opera Ball.

KHS SATISFIES DEMANDING

REQUIREMENTS

Perfect keg cleaning and gentle filling guar-antee the best wine quality in the keg. Cel-lar Master Arndorfer: “We have relied specif-ically on KHS keg technology for many years.”It’s precisely wines like the fruity GrünerVeltliner for which it is important to retainthe natural effervescence. Only gentle fill-ing reduces the pickup of gas and oxygeninto the wine to an absolute minimum.

After delivery, the empty kegs passthrough the Innokeg AK 1 external washer.

A spray nozzle system cleans the outsidesurfaces with caustic and warm water. Thecleaning times can be regulated individu-ally depending on the degree of contami-nation of the kegs. Then the fresh waterspray removes any remaining cleaning agents.An integrated control system monitors theexternal cleaning process.

The clean kegs then move on to thesingle-lane Innokeg Till TRANSOMAT 3/1washing and racking machine. The KHS kegline installed at Winzer Krems works on aone-shift schedule, filling up to 60 kegs perhour.

The Innokeg Till TRANSOMAT 3/1 isnot only able to fill red and white wines; itis also capable of filling of champagne inkegs ranging from 7 to the 58 liters in size.Cellar Master Franz Arndorfer: “We focusconsistently on the market. If, in the future,the end consumer wants wine in kegs insmaller container sizes, then we are just asopen to this as we are to an increased demand

by the restaurant trade for sparkling winein kegs.”

It remains to be noted that with kegtechnology, Winzer Krems is ready for futurepioneering in this sector.

Michael Schlegel, Central Product Support,


Volker Geng, Manager KHS Austria, Wiener Neudorf

* Cooperative founded in 1938

* Today Austria’s largest producer of quality wine* 1,300 vintners* Strict quantity limitation and strict quality testing* Production volume of 10 million liters per year* 1,250 hectares of vineyards under cultivation, 70%in white wine grape varieties such as Grüner Veltliner,Riesling, Chardonnay, Müller-Thurgau, Pinot Blanc,and Muscatel, and 30% in red wine grape varieties,including Blauer Zweigelt, St. Laurent, Blauer Bur-gunder, and Blauer Portugieser.

THUMBNAIL PORTRAIT: WINZER KREMS2

• WEBSITE www.winzerkrems.at• CONTACT

Michael Schlegel, Central Product Support, KHS AG, Bad KreuznachTel: +49 (671) 852-2764E-mail: [email protected] Geng, Manager KHS Austria, Wiener Neudorf Tel: +43 (22 36) 62510-229E-mail: [email protected]

INFOBOXfi

task+solution ° Winzer Krems: Austria’s largest viticultural cooperative has a tradition of innovation


Oil and water – as we know from basic chemistry – don’t mix. AtJazak Mineral Springs in Serbia, exactly the opposite is the case:here, oil and water attract. That’s because the mineral springs, asa subsidiary of Nis-Naftagas, belongs to Petroleum Industry Ser-bia. Although Nis-Naftagas, founded in 1949, primarily exploresand develops oil and gas f ields, it is also specialized in waterresources. Slavoljub Stojanovic, the CEO of Jazak, lists four signif-icant success factors, which make this combination of oil and waterso attractive.

1. Success factor: Know-how. What company, asks Stojanovic,is in a better position to know about ground conditions of the land,and therefore about the location of water sources, than an exploratorycompany like Nis-Naftagas? Before Jazak Mineral Springs opened,Nis-Naftagas started several selected drillings. The result: Nis-Naf-tagas discovered a source with outstanding mineral water qualityin the town of Jazak in the north of Serbia, in the Serbian provinceof Vojvodina.

THE TASK Sate-of-the-art PET system technology

• with options for expansion and

• service from one source.

THE SOLUTION

Two complete KHS PET bottling lines

• modular in design,

• able to fill 0.5 up to large-size 5 liter PET bottles.

2

1

Perfect Connection Jazak Mineral Water, Serbia: The slightly different success story

Jazak Mineral Water had its very successful start in Serbia-Montenegro. For their continued growth, the company is relying on innovative KHS PET filling technology.

2. Success factor: Quality. Jazak mineral water is known for itsexcellent quality, due, among other things, to its good calcium tomagnesium ratio (76.1 mg/l calcium, 42.5 mg/l magnesium) andits low sodium content of 8.3 mg/l.

3. Success factor: Marketing network. The group PetroleumIndustry Serbia works closely with filling stations to market fuel.Hence, since 2005, about 1000 filling stations sell not only thegroup’s fuel, but also its mineral water.

4. Success factor: Employees. CEO Stojanovic sees the largenumber of employees in the overall group as another marketing vol-ume reservoir. They not only can drink their own water, but alsoact as multipliers to report on the advantages of the water.

GREAT MARKET POTENTIAL

In the final analysis, it is naturally the good prospects for growth,which make the mineral water a profitable business for the group.The per capita consumption of bottled water in Serbia and Mon-tenegro is currently about 50 liters per year. If the development ofwater consumption over the past decade is examined, it becomesclear that the water market still has potential. For instance, in1996, consumption of bottled water was only about 16 liters percapita. In 2003, that figure was already 44 liters. According toStojanovic, a convergence with western European consumption lev-els is entirely conceivable. That would equal a per capita consump-tion of nearly 100 liters.

SALES HIT: 5-LITER PET BOTTLE

Jazak uses only PET bottles. Besides the 1.5- and 0.5-liter bottles,



* Newcomer to the Serbian water market

* Highest quality requirements for product and processing

* Part of the group Petroleum Industry Serbia

* 2006: Sales of 42 million liters (planned)

THUMBNAIL PORTRAIT: JAZAK2

the 5-liter PET bottle is astoundingly their top seller. “Especiallyas a family bottle, the 5-liter PET bottle is extremely popular,” saysCEO Stojanovic. About 55 percent of all sales are realized by thisjumbo size, followed by the 1.5-liter bottle with 30 percent.

STRENGTH, SIZE, AND QUALITY

Strength, size, and quality – those are also the criteria determinedby Nis-Naftagas for the selection of the bottling and packagingtechnology for the mineral water. Slavoljub Stojanovic says: “WithKHS, we are dealing with an equal partner, who has worldwide know-how and the best references in its sector.”

The company has invested in two KHS turnkey lines. KHSsupplied all the technical equipment. While one line processes the1.5-liter and 0.5-liter PET bottles at an output of 9,000 1.5-liter PETbottles/h, the second line is designed to process 5-liter PET bot-tles at 1,800 bottles/h. Both lines in brief:

PERFECT SOLUTION 1: THE 5-LITER PET LINE

* The highlight is the rinser-filler block for non-carbonated min-eral water (completely glass-enclosed, maximum microbiolog-ical safety).

* Computer-controlled normal pressure filling system InnofillNRF (bottom-up, gentle filling).

* Simple, fast cleaning (all surfaces from the ring bowl to thefilling valve are smoothed, with membrane technology in thevalve area).

PERFECT SOLUTION 2: THE 0.5/1.5-LITER PET LINE

* Rinsing process using mechanically controlled, single-channelInnoclean FR-EM rinser.

* Single-chamber pressure filling system Innofill DMG (non-car-bonated and carbonated mineral water and soft drinks).Rugged, simple handling and high product quality.

* Blending system Innopro Paramix CMX deaerates, doses, mixes,and carbonates soft drinks in a single unit.

* Innocheck CL checks filling levels and caps.* Innoket Roland HS 10 hotmelt labeling machine (sheet-feed

wrap-around labels).* Innopack Kisters PSP 035 pad shrink packer (pad shrink packs,

or shrink packs).* Innopal PBN palletizes shrink pads or pad shrink packs (robot-

controlled, modular dry area concept).

THE RESULT: PERFECT QUALITY

“Both lines satisfy our high quality expectations to the maximumpossible extent,” summarizes Stojanovic. The new KHS line tech-nology gives Jazak what it needs to conquer the domestic mineralwater market. There are currently about 40 different mineral waterbrands on the market in Serbia and Montenegro. Jazak not onlywants to remain one of them, but also to become the most success-ful brand of mineral water. Stojanovic: “With the help of our strongparent company, Nis-Naftagas, we can succeed in this more quicklythan you would think.”

Manfred Keller, Sales Manager South-East Europe, KHS AG, Bad Kreuznach

Nenad Delovski, Manager of the KHS Branch Office Belgrade, KHS AG

• WEBSITE www.nis-naftagas.co.yu• CONTACT Manfred Keller,

Sales Manager, South-East Europe, KHS AG, Bad KreuznachTel: +49 (671) 852-2655E-mail: [email protected] Delovski,Manager of KHS’ office in Belgrade, KHS AGTel: +3 (81) 113119-725E-mail: [email protected]

INFOBOXfi

Slavoljub Stojanovic, Managing Director of Jazak mineral

springs: “KHS equipment satisfies our high quality expectations

to the maximum possible extent.”


The brewery has a slogan that can be expressed in a simple sentence:The art of brewing at its finest. No more and certainly no less is prac-ticed by the Stiegl Brewery with headquarters in Salzburg. For over500 years a quality philosophy has prevailed here, which began inthe middle of the old town of Salzburg in 1492 in the former Prewhausauff der Gestetten and bey dem Stieglein (the little staircase).

As the best-known son of the town on the Salzach, Wolf-gang Amadeus Mozart, recorded in his diary, the Stiegl Brewery wasalready almost 300 years old when he visited it together with hissister Nannerl in 1780. Whether the art of brewing provided inspi-ration for Mozart for one or other of his musical compositions canneither be confirmed nor denied. However, it is certain that themaestro is a welcome inspiration for the Stiegl Brewery – not onlyin the Mozart year 2006. At any rate, Master Brewer Ernst Schreinerviews this pragmatically: “The Stiegl Brewery has a quite definitelocation advantage in the Mozart town of Salzburg.”

And the brewery consistently uses this with a certain kick: * The Mozart motif – and how could it be otherwise – has been

created for the (annually produced) art of brewing bottleedition.

* A year earlier, the brewery encouraged students at the Univer-sity of Applied Art in Vienna to develop Mozart labels. With327 designs, the jury was able to draw on plentiful resources.

* The ‘Mozart 2006’ edition has made an appearance at all of thisyear’s Mozart events in Salzburg.

THE TASK Partial replacement of a 20-year-old line

• using the latest technology

• with extensive flexibility.

THE SOLUTION The use of modular high-tech

components

• and the deployment of an additional rinser

• to form a combined refillable/non-refillable line.

2

1

The more than 500 years young SalzburgStiegl Brewery is repeatedly in the news with

publicity-oriented innovations. That such a strat-egy should pay off is shown by the record sales in

the month of July: 95,000 hectoliters – the highest salesf igures in half a millennium. And all this in Mozart year,

to which the Stiegl Brewery has dedicated a number of its in-spiring ideas.

The success story of the Stiegl Brewery,

Salzburg, goes merrily on

Record in


* Brewer of beer for more than 500 years

* Main brand: Stiegl-Goldbräu

* Market share in Austria: 11 percent

* Brand awareness: 91 percent

* Output 2005: more than 900,000 hectoliters

* The www.mozart.at website initiated by the brewery providesnews, information, and events on all aspects of Mozart.

* At www.mozartland.com, Mozartland, a 100-percent subsidiaryof the Stiegl Brewery, mainly provides opportunities for shop-ping.

The company also demonstrates creativity with the recently intro-duced 0.33-liter non-refillable glass bottle. Young adults in par-ticular are enthusiastic about the container with its retro-look stylingand a label in the Stiegl style of the 1960s. Marketing ManagerMarkus Oberhamberger explains: “As a private Austrian brewery, wehave confidence in ourselves and take a different path from theinternational brewery groups. We are once again living up to thisclaim with our new 0.33-liter bottle.” And Ernst Schreiner adds:“Modern packaging and retro-design harmonize here in accordancewith the motto: Opposites attract.”

BREWING AND CULINARY ART COME TOGETHER

In this sense, Stiegl is cooperating with domestic culinary art at itsfinest. For, according to the brewery, Stiegl beer specialties arenot only suitable for pure enjoyment, but equally for cooking aswell. A brochure with the title Koch- & Braukunst auf höchster Stufe(The Art of Cooking and Brewing at its Finest) has now been pub-lished in cooperation with master chef Simon Taxacher. Especiallydesigned for the restaurant trade, this standard work provides deli-cious beer recipes for the reader to make. Demand is enormous.Four reprints have therefore already been commissioned. The pub-lication includes fine beer recipes for asparagus, for broiling andfor various uses of mushrooms, all presented by Austrian masterchefs. It goes without saying that there is a recommendation bythe Master Brewer for the most appropriate beer for every meal.

LARGEST PRIVATE BREWERY IN AUSTRIA

The Stiegl Brewery has an 11 percent share of the beer market and isthus the largest private brewery in the country. In spite of a gener-ally stagnating beer consumption in Austria, the brewery is showing

task+solution ° 30*31

THUMBNAIL PORTRAIT: STIEGL BREWERY2

A record of a particularly special kind was recorded in June 2006. Mozartyear and the soccer World Cup proved to be an especially successful com-bination and brought the Stiegl Brewery its highest monthly sales in itsmore than 500-year history: 95,000 hectoliters.

MOZART PLUS WORLD CUP EQUALS MAXIMUM PERFORMANCE2

a continuous increase in sales. Schreiner predicts: “We are also expect-ing an increase again this year.” The sales figures are interesting:

* 1990: 500,000 hectoliters* 2000: 700,000 hectoliters* 2005: more than 900,000 hectoliters.

Although the Stiegl Brewery offers a truly comprehensive range ofbeer varieties including Märzen, Pils, Zwickl, wheat beer, specialbeer, bock beer, light beer, Paracelsus (bio-beer) and shandy, it con-tinues to be the Märzen beer known as Stiegl-Goldbräu that partic-ularly takes the fancy of the Austrians. The company realizes morethan 90 percent of total sales with this style of beer. Among otherthings, Schreiner believes that the reasons for this lie in the past.“In Austria, softer beers such as the Märzen beer have always beenparticularly popular. This goes back to the time of the monarchy.”

Mozart Year


Output up to 40,000 bottles per hour. Today, the line is oper-ated with an output of 28,000 0.33-liter non-refillable and 24,0000.33-liter or 0.5-liter refillable bottles per hour. With the newmachine components, an output of up to 40,000 0.33-liter bottlesper hour or 35,000 0.5-liter bottles per hour would be entirely fea-sible. The limiting factor here is the existing machines, namely thelabeler and the bottle washing machine. The successful harmonybetween old and new became clear during the acceptance of theline: The efficiency was 98 percent.

A mechanically controlled Innoclean FR-ZM double-chan-nel rinser handles the task of rinsing the non-refillable glass bot-tles. It is designed for rinsing with two different types of media.After disinfection with chlorine dioxide, the bottles are rinsed withsterile water. Low-oxygen-pickup filling saves CO

2. The computer-controlled

Innofill DRS-ZMS pneumatic pressurized filling system is equippedwith 108 filling stations and guarantees the high quality of theStiegl Brewery’s beer due to the extremely low oxygen filling process.It allows new sizes and shapes of bottle to be processed at any timeand works with filling level probes. The CO2 consumption is an excel-lent 230 grams per hectoliter of beer; the O2 pickup is a very good0.02 mg/l. Other benefits include short changeover times, highmachine availability through central filling level adjustment, speed-

The Brewery mainly sees its market in Austria and brews the beer ofthe Austrians. The export share is just one percent. Export countriesare Germany, Italy, the U.S.A., and Canada. The Master Brewer: “Westill see a great deal of potential on the domestic market. Added tothis is the fact that, as a company that practices the art of brewingat its finest, we want to be local to our customers in order to be ableto provide a correspondingly top level of service quality at all times.”

The in-house Quality Service Department for the restauranttrade is also geared towards this. With this department, the StieglBrewery traditionally provides a unique service. The aim of thequality team, which is active throughout Austria, is to raise andsecure the level of beer culture in restaurants.

AND A TOP-LEVEL TECHNICAL SOLUTION

Quality is also the most important aspect of bottling and packag-ing the quality beers. “Our quality strategy,” says Schreiner, “onlyallows the best technical solutions to be used. We will not be sat-isfied with less.”

It was obvious to Schreiner that it would once again haveto be KHS for the most recent investment. On the one hand, thelatest technical solutions, which could be visited in advance at ref-erence installations by the Stiegl Brewery team, were very convinc-ing. On the other, KHS equipment has impressed over and overagain in the company’s own plant for many years. The company hasjust recently invested in the latest KHS bottle washing technology.The new single-end bottle washer processes 72,000 bottles per hourand offers considerable savings on water, energy, and cleaningmedia while maintaining excellent cleaning action.

Investment is currently being made in the replacement of awide range of modules: Rinser-filler-capper block, flash pasteurizer,inspection equipment, and crater on a former refillable line, whichhas now advanced to become a combined refillable/non-refillablebottle line by installing an additional rinser. On the other hand, tried-and-tested KHS equipment, which has unhesitatingly provided out-standing service for more than two decades, has been discarded.


32*33task+solution ° The success story of the Stiegl Brewery, Salzburg, goes merrily on

and standstill-independent processing sequence, adjustment tosuit the current line output, freedom from external mechanical con-trol devices, and aseptic sealing systems in all product and gas pas-sages. Master Brewer Schreiner praises: “It doesn’t get any better.We are more than satisfied with the bottling results.”

A further highlight in the filler area is the integrated ReDiS(Remote Diagnostic Service) remote maintenance system.Crown corks and screw caps possible. The filler system is blockedwith a crown cork capper for non-refillable and refillable bottles,and a ring-pull capper especially for 0.33-liter refillable bottles. Aninteresting item: An interesting feature is the twist crown cork capfitted to the bottles by the crowner. It is especially liked by theyoung target group on the 0.33-liter non-refillable bottles.Exact filling level and cap checking. Immediately after thefilling and capping process, the bottles pass to the InnocheckPROMECON 2000 filling level and cap monitor where the fillinglevel is checked using x-ray technology, the presence of the capis checked using a sensor, and the seating of the cap is checkedby means of a laser light barrier.Fully automatic format changing system. Good bottles go tothe Innopack PPZ crater, a latest generation twin-axis machine withoutstanding accessibility, simple controls, and a fully automaticKHS format change system. All format part changing for complete

• WEBSITE www.stieglbrauerei.at• CONTACT

Günter Unkrig, Director, Central European Sales Region, KHS AG, DortmundTel: +49 (231) 569-1602E-mail: [email protected] Geng, Manager KHS Austria, Wiener NeudorfTel: +43 (2236) 62510-229E-mail: [email protected]

INFOBOXfi

Left Innofill DRS-ZMS: Safeguards the high quality of the Stiegl Brewery’s beer

by means of the extremely low-oxygen filling process. Center All from one

source: KHS supplied the process technology as well as the flash pasteurizer.

Right Filling level probe: Accurately determines the filling level.

Bottom “KHS has taken our high quality requirements fully into account,”

says Ernst Schreiner, Stiegl Brewery’s Master Brewer (left) to Volker Geng,

Manager KHS Austria.

pack sets is carried out at the press of a button. The gripper head,centering belts and lanes previously used are parked fully automat-ically; new components are then picked up and installed one afterthe other in the packing machine – also fully automatically. Theonly manual intervention necessary is to couple the connectinghoses for the power and air supplies.

HIGH PRAISE FROM THE MASTER BREWER

Ernst Schreiner emphasizes once more: “We are extremely satisfiedwith KHS solutions. KHS has taken our high quality requirementsfully into account.” This way, the success story of the Stiegl Brew-ery continues in the same vein. Incidentally, in 2007, for the firsttime, the entire population of Austria (instead of a jury) will decidewhich six labels are to appear on art-of-brewing edition bottles.Stiegl is certainly the brewery from and for Austria.

Günter Unkrig, Director, Central European Sales Region, KHS AG, Dortmund

Volker Geng, Manager KHS Austria, Wiener Neudorf


Voda Voda: Unique overall concept

WATER TO THE Water is precious. But only a few sources have such quality as that in Serbian Banja Vrujci. Reasonenough for the indigenous SI&SI Group to bottle their Voda Voda spring water in elaborately designedwater bottles and along the way to thoroughly stir up the domestic water market.



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Some products present marketing experts with a great challenge.For, at first sight, these products cannot be distinguished from oneanother. Surely, the most demanding product in this regard is water.It is odorless and colorless and even the carbon dioxide content isimpossible to detect before the water sparkles in the glass.

The matter is not made any easier by the fact that shares inthe water market are strongly contested and new suppliers find itdoubly difficult to establish themselves. But exactly this challengehas stimulated Vojin Djordjevic, President of the SI&SI Group in Ser-bia and Montenegro. He has accepted it and overcome it with gusto.Djordjevic has helped a unique spring water from Banja Vrujci –located at the foot of the Suvobor Mountain on the Toplica River –to achieve a breakthrough in just two years with a unique market-ing strategy.

The Vrujci source there has been known since the end of the19th century, and the people of Banja Vrujci attribute healing andbeneficial effects to the spring water. Entrepreneur Djordjevic seesthis rather more pragmatically: “Numerous analyses by nationaland international institutions have confirmed the traditions andshow that the source produces water of the best possible quality.”

His water has recently been awarded the renowned American NSFcertificate by the independent National Hygiene Foundation. Theupshot in any event is that the water has the potential to refreshconnoisseurs around the globe.

But how does one make it clear to the customer that thiswater is something special?

UNIQUE: THE NAME

Individuality and the promotion of a product begin with the name.Djordjevic has christened his precious liquid, and indeed the com-pany – quite simply Voda Voda. And, translated, this means WaterWater.

UNIQUE: THE BOTTLE

Another important element in the integrated marketing concept isthe bottle itself. It is not round, but square; it bears the Voda Vodainscription embossed in relief, and takes one by surprise with a clearno-label-look adhesive-pressure label.

UNIQUE: THE MARKET POSITION

Voda Voda is already the market leader in the still mineral watersector in Serbia and Montenegro. Sales have climbed from 10 mil-lion liters two years ago to 30 million liters last year, and this yearVoda Voda is aiming for the 50-million-liter mark. According toDjordjevic, things are expected to continue with similarly large salesincreases. Later this year, the company intends to launch a sparklingmineral water version with the name Voda Voda 2.

Since the beginning of the year, the non-carbonated waterhas not only been bottled in PET but also in glass bottles. This isexpected to greatly improve sales in the restaurant trade in partic-ular. Glass bottles are currently only available on the market in the0.33-liter version. The 0.75-liter glass bottle is to be added later.In PET, Voda Voda uses the 0.5-liter and 1.5-liter sizes, which intotal account for 75 percent of sales. The proportion of glass andPET bottles are later expected to balance out.

UNIQUE: THE PRODUCTION FACILITY

Also sophisticated and spectacular are the Voda Voda bottling shops,for the factory bays are basically more design objects than produc-tion facilities – the ideal location for bottling the extraordinaryspring water. What is more, the water passes almost directly fromthe source to the bottle – without any processing and without longtransport routes through pipes. There is a height difference of

POWER OF THE TASK Installation of a complete glass bottling line

• for square bottles and

• adhesive-pressure labeling.

THE SOLUTION A complete KHS system with

• gentle, single-lane bottle conveying and

• an Innoket Roland adhesive-pressure labeling machine.


Voda Voda: Unique overall concept

• WEBSIDE www.vodavoda.com.sg• CONTACT

Manfred Keller, Sales Manager South-East Europe, KHS AG, Bad KreuznachTel: +49 (671) 852-2655E-mail: [email protected] Delovski, Manager of the KHS Branch Office Belgrade, KHS AGTel: +3 (81) 113119-725E-mail: [email protected]

INFOBOXfi

* Serbia’s market leader for non-carbonated water

* An SI&SI Group company* Output: 2004: 10 million /2005: 30 million /2006:

50 million liters (estimated)

SI&SI GROUP

* Subsidiaries: Voda Voda /Podrum Palic (one of the largestwine cellars in Serbia) /Gorki List (most important Serbianherbal liqueur)

* Joint Venture with Sinalco International (Sinalco Serbiaproduces immediately next to Voda Voda – and values the outstanding water quality of Voda Voda for its own bev-erages).

THUMBNAIL PORTRAIT 2

* Completely enclosed rinser-f iller-capper block with theInnoclean FR EM rinser blocked with the Innofill DMG fillerand capper.

* Innocheck CL filling level and cap checking.* Four-lane Innopack Kisters PSP 035 B pad shrink packer.

UNIQUE: THE COOPERATION:

Company boss Vojin Djordjevic: “The confident cooperation withKHS has continued in the most positive sense with the new plantequipment. We are highly satisfied. Innovative KHS equipment isan important basis for a very special and continuing Voda Voda suc-cess story.” An international success story – of course.

Manfred Keller, Sales Manager South-East Europe, KHS AG, Bad Kreuznach

Nenad Delovski, Manager of the KHS Branch Office Belgrade, KHS AG

exactly 273 meters that the precious liquid needs to negotiatefrom the source in the depths to the filler, which is almost directlyabove it.

UNIQUE: THE BOTTLING EQUIPMENT

The sophisticated bottle shape and the outstanding water qualityalso demand correspondingly high-quality technical solutions forfilling and packaging. The finest KHS equipment is also part of thestory. “The best is just good enough,” Djordjevic demands andcontinues, “We have used KHS equipment within the SI&SI Groupfor several years. To the present day, we are highly satisfied withthe technical solutions and service from KHS. We have a partner-ship with KHS just as it should be.”

The best features of the new line in brief:

* Capacity 10,000 0.33-liter glass bottles per hour. * Innopal ASN new-bottle depalletizer, closed in on four sides,

gentle conveying thanks to handling robots and cladding withplastic panels.

* Innoket Roland 16 H adhesive-pressure labeler with a speciallydesigned feedscrew for square bottles.

Left Less is more: Glass bottle only with no-label look front label.

Right Vojin Djordjevic, President of the SI&SI Group: “Innovative KHS equipment

is a very important basis for our success story.” Bottom Rinsing process:

Innoclean FR-EM single-channel rinser.



Saudi Arabia’s Pepsi bottler with high-performance canning lines

The high-performance canning line delivered by KHS for Saudi Industrial Projects Co. (Sipco for short), with an output of up to90,000 cans per hour, is a textbook example for the Saudi soft drink industry. In the past four years alone, this licensing partnerof Pepsi-Cola has ordered five of these lines. Sipco: the model case.

Sipco Sets an Example

In Saudi Arabia, too, KHS has a proud tra-dition. Many KHS filling lines from the 80s,particularly those for soft drinks, are still run-ning here today to the full satisfaction of theiroperators. And, the market for these bev-erages is firmly in Pepsi’s hand. Pepsi-Cola,Seven Up, Mirinda, Shani, and Mountain Dewhave a market share of more than 90 percent.Particularly the younger generation consumessoft drinks, primarily in cans. They are attrac-tive due to convenience and protection ofthe product at high temperatures. In the past four years, KHS has shipped sixhigh-performance canning lines to Saudi

Arabia. Five of those were ordered by fran-chising partners of Pepsi-Cola International.One system went to the Abuljadayel bottlingplant in Jiddah, a major producer of fruitjuice and energy drinks. Pepsi-Cola Inter-national has four licensing partnerships

in Saudi Arabia:* In Riyadh, the largest city in Saudi Ara-

bia with 4.1 million inhabitants, Al

Jomaih Bottling & Can Making Co.

produces for the central and northernregions of the country.

* Saudi Industrial Projects Co. (Sipco)

is based in Jiddah on coast of the Red

2

1 THE TASK

An optimum Pepsi-Cola filling sys-

tem for Saudi Arabia that

• considers the conditions of

the country,

• sets standards,

• leaves room for individuality.

THE SOLUTION Ultra-modern

can filling technology that

• offers high line efficiency,

• establishes national standards,

and

• is still highly flexible.


Sea (2.8 million inhabitants, secondlargest city, western region).

* Abdel Hadi Abdallah Al Qahtani &

Sons in Khamis Mashayt (southwestregion).

* Ahmed Hamad Algosaibi & Bros.

National Bottling Co. has its head-quarters in Al Khobar on the Gulf ofArabia near the large city of Dammam(eastern region).

From 2003 on, the KHS success story hascontinued with the delivery of a high-per-formance canning line to Saudi IndustrialProjects Co. (Sipco) in Jiddah. Here, thepartners are setting an example with state-of-the-art technology, in the truest senseof the word. The system processes 90,000cans per hour and runs in three shifts. Theline efficiency remains in the high ninetieseven today.

TOP STANDARD FOR THE

ENTIRE COUNTRY

A truly impressive performance. Praise fromA. Amer S. Morshed, General Manager Sipco:“We expected KHS quality with the bestresults, but our expectations were evenexceeded. For us, it was therefore naturalto use only KHS turnkey systems for addi-tional f illing systems.” Sipco ordered asecond KHS high-performance canning linein 2004. Oriented towards this ‘Sipco Model’that has become a standard, a canning linewent to Al Jomaih Bottling & Can MakingCo. in the same year. And recently, AbdelHadi Abdallah Al Qahtani & Sons and AhmedHamad Algosaibi & Bros. National BottlingCo. also both ordered this type of modelsystem.

Of course, always customized to thewishes of the customer. Even at Sipco, the

two newest plants are not identical to thelast detail. They process the 0.355-litercan, which is particularly popular in SaudiArabia for Pepsi brand beverages. The linesrun in parallel with one another – thatsaves space.

THE ‘SIPCO MODEL’ IN 10 STEPS

Empty cans enter the lines by thepallet. An operator removes the

securing straps. An Innopal ASH can depal-letizer is in operation for each of the twolines.

The system sorts faulty cans out usinga vacuum bridge. Good cans are con-

veyed directly to the appropriate rinser(mounted diagonally), which moves the cansdown to the height of the filler during thecold water rinse.

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38*39task+solution ° Saudi Arabia’s Pepsi bottler with high-performance canning lines

The heart of the line, a computer-con-trolled Innofill DVD volumetric filler

system, stands for maximum filling level accu-racy using electromagnetic induction flowme-tering. Deviations in can capacities suppliedby various manufactures are no longer a mat-ter of concern. This saves a considerableamount of product. Different can variantscan also be processed – at the press of a but-ton. Advantages: Time savings and increasedmachine availability. Format part changingis necessary only if a different can diameteris to be processed. Blocked: The seamer.

The precision fill level and sealingcontrol system is next. Also Inte-

grated: filling valve management.

The Innopro Paramix CMX double-deaerating, mixing, and carbonat-

ing system works with a Brix measurementand control system.

After the filling and seaming process,the cans are turned upside down and

conveyed to the Innopas can heater wherethe cans, filled at a product temperature of15 degrees Celsius, are heated to about 30degrees. Indispensable in an environmentwith peak temperatures of up to 50 degreesand high humidity in order to avoid conden-sation on the cans.

Standing on their heads, the cans arethen sent to the coding unit. Any liq-

uid clinging to the outside of the cans isblown off before an inkjet printer applies aspecial can code.

After uprighting the cans in the twister,they travel towards the packing and

palletizing system, which has different lay-outs in the two lines (1 shrink packer/2 trayshrink packers/2 palletizers vs. 1 InnopackKisters TSP 100 V tray shrink packer and 1high-flexibility palletizer).

The new KHS Innopal PBHS high-per-formance palletizing system is a sin-

gle-station robot with pallet elevator aboveand a two-piece pusher plate with a maxi-mum capacity of up to 700 layers per hour.

The newer line is already designedaccording to the modular dry area

concept with PC-based robot controls. Onlya single intelligence is used here.

PARTNERS HIGHLY SATISFIED

Ron Beatson, Sipco’s Plant Manager, sum-marizes: “We are and will remain KHS fans.It’s no coincidence that a large part of Sipco’splant engineering is from KHS.” Elie J. Fayad,

General Manager Al Jomaih Bottling & CanMaking Co., is also enthusiastic about KHStechnology. This franchising partner ofPepsi-Cola International took delivery of acanning line at nearly the same time as Sipco.Elie J. Fayad: “The KHS concept for Sipcohad us convinced. We just wanted a fewoperation-specific adaptations on our end.”More can sizes for instance – from 150- and250-milliliter slim cans up to 330- and 355-milliliter standard cans. Or the transfer ofthe packaged cans to the palletizer: It runsmore than 250 meters over a bridge to theother side of the street.

And the KHS success story in SaudiArabia hasn’t ended yet: Aduljadayel tookdelivery of a high-performance canning line– based on the ‘Sipco Model’, of course –and also ordered a non-refillable glass linedesigned for an output of 72,000 bottles perhour. KHS quality is compelling.

Erhard Magin, Director for Africa,

Middle East, and Southern Europe Sales Region,


Manfred Seifert, Middle East Sales,


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• WEBSIDE www.pepsico.com• CONTACT

Erhard Magin, Director for Africa, Middle East,and Southern Europe Sales Region, KHS AG, Bad KreuznachTel: +49 (671) 852-2675E-mail: [email protected] Seifert, Middle East Sales, KHS AG, Bad KreuznachTel: +49 (5704) 16050 E-mail: [email protected]

INFOBOXfi

Left United Arab Emirates – Saudi Arabia – Jiddah: Architectural minaret mosque tower.

Right Front view from right: DVD 126 can filler with Ferrum F812-2 seamer.


2

1 THE TASK

Provide suitable systems for the filling of Pepsi-Cola very quickly

based on market demands.

THE SOLUTION PET and can filling equipment in several

lines, with partly identical components, based on the latest in

technological standards.

In Iraq, water is the most popular drink, followed closelyby tea and soft drinks. In the latter category, the clearfavorite is Pepsi-Cola (the bubbly beverage has been inthe country since 1950). The most important franchis-ing partner of Pepsi-Cola International in Iraq is Bagh-dad Soft Drinks, with headquarters in the capital cityof Baghdad. Operations started in 1984 with the pro-duction of Pepsi-Cola and the soft drinks 7-Up andMirinda, both members of the Pepsi brand family. Alreadyin use at that time: eight refillable glass bottle lines,along with one canning line, all from KHS.

But in 1991, the United Nations embargo cutthe company off from its supply of concentrate. The UNsanctions were not lifted until 2003 – the beginning ofa new Pepsi era. In the meantime, the distributionregion of Baghdad Soft Drinks includes the city of Bagh-dad, with five million inhabitants, along with its north-ern vicinity. That means the company reaches about40% of the 27 million inhabitants of the country.

6 Lines in 2 YearsPepsi-Cola, Iraq: Licensing partners placing trust in KHS equipment

The four licensees of Pepsi-Cola International in Iraqfill their beverages nearly exclusively using systemsfrom KHS. Within the past two years, they haveinvested in six lines. The last were one PET bottlingline and one canning line.


task+solution ° 40*41

Today, Pepsi-Cola International has another three licens-ing partnerships in Iraq: in Al Kufah (100 kilometersfrom Baghdad), in Basra (with a population of two mil-lion people, the second largest city in the nation, andthe center of the Shiite south), and soon in Arbil (thecapital of the autonomous region Kurdistan, with aboutone million inhabitants.)

QUALITY OVER DECADES

When Baghdad Soft Drinks reemerged as a franchisingpartner of Pepsi-Cola International in 2004, a new KHSera started there as well. The most important reason:great satisfaction with KHS system technology from theyear 1984, which served faithfully for decades and tosome extent is still working today. But markets change.Refillable glass bottles continue to be the style of pack-aging of choice in Iraq although it is slowly starting tolose ground to cans and PET bottles.

And KHS technology has always been there.Since 2004, when KHS experts refurbished the 20-year-old canning equipment, KHS has installed* a new PET line first,* then a refillable glass bottle line,* a canning line, and* in early 2005, PET and canning systems again at

Baghdad Soft Drinks, with components identical tothose used in the solutions delivered in 2004.

Dr. Hamid Jassim Khamis Hamed, Managing Director atBaghdad Soft Drinks, explains: “Excellent KHS systemtechnology needs no improvement.” The board of NationalBottling Company in Al Kufah sees it the same way. Here,too – as with the other Pepsi licensing partners – KHStechnology has been in operation for years. And thecurrent new canning and packaging technology is onceagain from KHS.

PET TECHNOLOGY

In Iraq, PET means large-size bottles. That’s the orien-tation of KHS PET system technology for Baghdad SoftDrinks. The system processes both 1.5 and 2.25-literPET bottles. The filling capacity is 12,000 1.5-liter or10,800 2.25 liter bottles.

Special features:

* A radial fan specially integrated into the air chan-nel of the air conveyor reduces flow losses and savesenergy.

* Labeling of bottles before the filling process(Innoket RF 25).

* The mechanically controlled pressure filling systemInnofill DMG-VF is predestined for filling of softdrinks in PET bottles.

Director Hamed: “The robust, low-maintenance, andextremely user-friendly KHS filling system completelysatisfies our requirements for high-quality filling results.For this reason, we have also decided to use the corre-spondingly adapted filling principle for our new KHSrefillable glass bottle line as well.”

CANNING TECHNOLOGY

The new KHS canning plant has a high capacity of 72,0000.33-liter or 86,000 0.25-liter cans per hour. Heart ofthe line is an Innofill DMD mechanical can filler. Whatmakes it stand out: rugged design, high capacity, bestfilling quality, extremely long service life, gentle fill-ing, low CO2 losses, minimal oxygen pickup, fast changeover,correction of filling levels without stopping, high avail-ability, high product savings.

Praise from Managing Director Hamed: “In addi-tion to optimum machine technology, KHS always pro-vides us with perfect consulting services. I’m speakingof a partnership, which simply could not be better. Andthe Pepsi potential in Iraq isn’t even close to exhausted.”The success story can continue.

Erhard Magin, Director for Africa, Middle East, and Southern

Europe Sales Region, KHS AG, Bad Kreuznach

Meinhard Fischer, Sales Africa, Middle East, and Southern Europe,


• WEBSIDE www.pepsico.com• CONTACT

Erhard Magin, Director for Africa, Middle East, and Southern Europe Sales Region, KHS AG, Bad KreuznachTel: +49 (671) 852-2675E-mail: [email protected] Fischer, Sales Africa, Middle East, andSouthern Europe, KHS AG, Bad KreuznachTel: +49 (671) 852-2631E-mail: [email protected]

INFOBOXfi


A natural healer invented a mix-ture some hundred years ago whichlater celebrated global success underthe name Sinalco. Today – after a pauseof nearly three decades – Sinalco is backin more than 50 countries. With an inno-vative keg solution, KHS is contributing to thepromising growth of the brand.

barely keep up with production. In the firstyear, Hartmann had already sold three mil-lion liters of Bilz-Seele. Two years later, saleshad reached 25 million liters.

THE FIRST TRIUMPH OF THE BRAND

In 1905, it was necessary to find a catchiername for the beverage. There were too manycopycats on the market. The decision wasmade for the name Sinalco – from the start-ing syllables of the Latin ‘sine alcohole’(without alcohol). The pleasant result: 80million liters sold in the year 1906.

The next year saw the beginning ofSinalco’s global conquest with distribution tomarkets in South America and the Middle East.The Sinalco bottle got its unmistakable reddot in 1937, was available in 50 countries, andwas bottled by 500 franchisees. The brandwas so successful, its name became a generic

Wonders never cease – humanity has knownthat at least since Morcheeba’s hit song. Asimilar miracle is the skyrocketing return ofSinalco – after the brand already spent afew decades in the retirement home of non-alcoholic beverages.

But one thing after the other. FriedrichEduard Bilz, along with priests SebastianKneipp and Johann Schroth the best-knownGerman representatives of the health move-ment of the early 20th century, mixed a drinkin the year 1902 from concentrates of seventropical fruits and domestic produce. Bilz-Seele was his original name for this healthelixir. “Highly recommended for stomach,rheumatic, and lung ailments,” said the bot-tle label at the time. Bilz obviously under-stood the tastes of the bulk of the popula-tion, because his marketing partner, Det-mold factory owner Franz Hartmann, could

THE TASK A keg line which

• can be expanded quickly,

• fills with the highest in quality

requirements, and

• allows seamless documentation

of keg data.

THE SOLUTION

Innokeg Till TRANSOMAT 5/1

• modular in design and

• with the hygienic pulsed spray

process and the

• Innokeg management system.

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KHS keg technology

involved in the global

comeback of SinalcoA Brand

Returns


term – those who wanted a soda pop in arestaurant ordered “a Sinalco”. This triumphheld until the 70s, and then the brand startedto fade. A series of new owners were unableto continue the success story.

THE SECOND TRIUMPH OF THE BRAND

It wasn’t until 1994 when Hermann Hövel-mann, managing owner of the Hövelmannbeverage group, acquired the rights to thebrand that the tide turned. In that sameyear, Deutsche Sinalco was founded, fol-lowed three years later by Sinalco Interna-tional. In 2002, one hundred years afterBilz invented his refreshing mixture, Hövel-mann brought the Sinalco bottle to marketas a 1-liter refillable PET bottle in yellowbrand crates – and Sinalco started its sec-ond triumph. In 2002, Sinalco sold 41 mil-lion liters in Germany, and in 2003, it was

already 100 million. Hövelmann investedfurther in the brand, introducing the 0.5-liter refillable PET bottle in 2004. The result:164 million liters sold last year. And in thecurrent year, Sinalco is now also availablein non-refillable PET bottles.

In the meantime, as in earlier days,Sinalco is again at home in more than 50countries around the world. In 2006, Nige-ria, Italy, Jordan, Egypt, Romania, Libya,Hungary, Sudan, Lebanon, and Cypress joinedthe list in rapid succession. The currentlymost significant foreign market is Serbia,where Sinalco holds a 30 percent marketshare. Only recently was a new Sinalco pro-duction operation opened, with an annualfilling capacity of 200 million liters.

Sinalco International grants fran-chise licenses for the use of brand rights toforeign bottlers, and supplies them with all

necessary ingredients, essences, and recipesfrom Germany. That ensures quality at thehighest level.

And that applies not only for theclassic Sinalco Orange, but for all the fla-vors of the brand family including cola,lemon, citrus, diet orange, diet cola, dietlemon, diet citrus, cola mix, apple cider, for-est fruit cider, and bitter lemon. With a 50percent share of total sales, orange and colaare the leaders. Sinalco has been repre-sented on the German market since 2003 bythe mineral water brand Sinalco Aquintéll.Under this brand, the company markets notonly classical mineral water, but also fla-vored mineral waters and a wellness drink.

RESTAURANTS: KEG IS KING

An important component of Sinalco’s suc-cess was and is restaurant sales. In 1970,its share of total sales of Sinalco in Germanywas still 70 percent. That was a long timeago, but Sinalco is ready to add a new chap-ter to the old success story – supported bya marketing cooperation with the Krom-bacher Brewery (since 2003). Last year,restaurant sales were 70,000 hectoliters.While in earlier years, bottles were usuallydelivered to restaurants, today 86 percentof the various Sinalco products flow intorestaurants from 10- and 20-liter kegs.


The Sinalco’s origins date back to the beginning of the 20thcentu

ry. Today, the

brand

ise

njo

yin

ga

na

tio

na

la

nd

inte

rna

tio

na

lre

bir

th.

* 100-year-old brand

* 1994: Relaunch by Hermann Hövelmann

* 2002: 1-liter refillable individual PET bottle

* Turnover:2002: 41 million liters2003: 100 million liters2004: 164 million liters

* Distribution to 50 countries

* Restaurants: filled primarily in kegs

THUMBNAIL PORTRAIT: SINALCO2


has five active cleaning and sterilizing sta-tions, along with one racking station, andis thus ideal for soft drinks requiring spe-cial handling. Its intensive cleaning powerensures maximum microbiological safety.“For us, the high microbiological safety isthe most important aspect of the innova-tive KHS keg system technology,” empha-sizes Sanchez.

The system cleans the interior kegsurfaces and the riser pipe with a pulsedspray process. The subsequent hot waterrinse removes any remaining cleaning agentadhering to the keg. Blowing the keg outwith hot steam concludes the cleaning process,removes residual liquid from the keg, ster-ilizes it, and at the same time drives anyremaining oxygen out – ideal conditions foran optimum filling process.

Likewise integrated are heat exchang-ers and culinary steam generators. Whilethe heat exchanger heats cold water andfeeds the media tank, the culinary steam

“The keg combines the advantages of lowspace requirements, simple handling, andmaximum hygiene,” says Axel Drösser, busi-ness manager of Deutsche Sinalco, aboutthe advantages of kegs to restaurants andlarge events. With a keg share of 90 per-cent, the 20-liter keg (and the premix vari-ants, too) have the lion’s share of restau-rant sales. For the postmix variants, the 10-liter keg sees more use.

KHS OFFERS HIGH-TECH KEGGING

EQUIPMENT

Due to the great success of kegs, Sinalcorecently invested in new KHS keg systemtechnology, with a nominal capacity of 80kegs per hour. A particularly importantrequirement of the new plant was its mod-ular design. If growth in keg demand con-tinues, this will allow problem-free augmen-tation of line capacity by a factor of three –by integrating additional washing and rack-ing lines. “KHS offered us high technology

and exactly the flexibility we need,” praisesFrancisco Sánchez, production and technol-ogy manager for the Hövelmann Group. Flex-ibility is important, for instance, when kegsmust be filled later for the internationalmarket. Because kegs also bring significantadvantages over bottles for export due tosimple, space-saving transport.

STATIONS OF THE KEG PLANT

Palletizing. At the present time, the kegsare still being palletized and depalletizedby hand, but even now, the modular designprovides the option of equipping the sys-tem with KHS robotic systems.Exterior cleaning. After depalletizing, thekegs enter the Innokeg AK 1 exterior washer.If additional washing and racking lines areintegrated later, the Innokeg AK 1 can cleanthe kegs even more quickly with the sameintensity.Interior cleaning. Interior cleaning is han-dled by the Innokeg Till TRANSOMAT 5/1. It

A Brand

ReturnsLeft Innokeg Till TRANSOMAT 5/1: One racking and five active washing stations.

Center All from one source: Innopro Paramix CMX mixing system. Right After depal-

letizing: The kegs are taken directly to the Innokeg Till AK 1 exterior washer

Far right Convinced by KHS keg system technology (left to right): Francisco Sánchez,

Manager of Production / Technology, Hövelmann Beverage Group;

Nicole Fischermanns, Product Manager for Deutsche Sinalco, and Dr. Axel Drösser,

CEO of Deutsche Sinalco.


task+solution ° KHS keg technology involved in the global comeback of Sinalco

generator ensures that the hot steam insidethe keg has a temperature of at least 125degrees Celsius. This is required to ensurethe needed sterilization effect. The entirecleaning process is monitored by a pressuresensor and a wet/dry sensor.Filling process. Before the filling process,any remaining condensation is blown out.The kegs are filled using a DFC (Direct FlowControl) process with volumetric flow con-trol. In this process, pressurization to apressure slightly above the CO2 saturationis enough. That reduces the consumptionof carbonic acid in comparison with tradi-tional filling solutions by up to 40 percent.The direct control of the filling process bya regulator valve on the product feed makesthe DFC filling process extremely precise.There are neither product losses due to over-filling of the keg, nor any problems withunderfilling. At the same time, product qual-ity is ensured due to only minimal oxygenpickup. The filling process starts with a slowinitial filling phase. The fast filling phasebegins once the fitting is covered with prod-uct. An additional protection for the prod-uct being filled is provided by the fillingvelocity control.

Installed upstream of the filling areaare an Innopro Paramix CMX blending sys-tem and an Innopro KZE flash pasteurizerspecially used for Sinalco apple cider. A heatexchanger cools the product filled to thepredefined filling temperature.Full keg scale. The filled kegs then moveonto the full keg scale. It detects empty orunderfilled kegs and controls the automatic

rejection of these kegs. The correctly rackedkegs are then palletized by hand and cappedand the collar labels are applied. In thisarea, too, there is the option of extendingthe system by installing KHS robotics.Keg management system. Another high-light: The system is equipped with theInnokeg keg management system. It workslike this: All Sinalco kegs have so-calledtransponders, which supply information tothe Innokeg keg management system. Beforea new keg is used, the central databasestores data about the keg, such as its tareweight, volume, type and date of manufac-ture, fitting type, and the fitting manufac-turer. All the data needed by Sinalco forefficient keg use can be stored in a datarecord this way. The filling system recordsthe entire product life of each and everykeg – that’s important for quality assur-ance at Sinalco. Before the washing processbegins, the keg transponder is read outand, based on data such as market dwelltime, number of fills, or the date of the lastinspection, a decision is made whether thekeg may be filled again. The result: onlyperfect kegs reach the line. And for a rejectedkeg, the operating personnel already knowthe reason for the rejection after a glanceat the recording terminal.

During the filling process, the data-base then stores the new information, suchas the type of beverage, lot number, fillingdate and time, fill volume, and the condi-tion of the media. The Innokeg manage-ment system also has a modular design andcan be extended, for instance with another

44*45

• WEBSIDE www.sinalco.com• CONTACT

Michael Schlegel, Central Product Support, KHS AG, Bad KreuznachTel: +49/671/852-2764E-mail: [email protected] Augel, Central EuropeanSales, KHS AG, DortmundTel: +49/231/569 -1635E-mail: [email protected]

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module for marketing logistics. Then thetransponder evaluation could also give someinsight into the current location or the timethe keg spends at the customer’s place ofbusiness.

READY FOR THE FUTURE

“The increasing success of Sinalco in restau-rants can now proceed perfectly, thanks tomodern KHS keg system technology,” pre-dicts CEO Axel Drösser. Hermann Hövelmannshares that opinion. He is convinced by thegrowth of the Sinalco brand family on theGerman and international market: “TheSinalco success story has only just begun.There is still a great deal of potential here.We will pursue our quality strategy just asconsistently as we do the Sinalco brand strat-egy. Ready for the future.”

Michael Schlegel, Central Product Support,


Wolfgang Augel, Central European Sales,

KHS AG, Dortmund


The Graf von Oeynhausen-Sierstorpff company group is working towards the complete health package, even in its seventh generation. And it’s doing that with perfection and a passion for topquality. For an individual refillable PET concept, KHS is once again the perfect partner: Supplier of a solution others wouldn’t dare to try.

German poet Friedrich Hölderlin was full ofpraise: “I used the bath a little and drankthe wonderfully strengthening mineral waterand I find myself extraordinarily fit as aresult.” The poet was in Bad Driburg, belovedfor centuries for its spa and bath facilities.Today, the Graf von Oeynhausen-SierstorpffGroup still offers a true end-to-end pack-age for the pleasure of guests and customersfrom near and far.

From a business standpoint, the com-pany’s action areas are quite practical: Min-eral springs, baths, and clinics. This com-plete health program, according to Marcus,Count von Oeynhausen-Sierstorpff, CEO ofOperative Management Holding, representsa clear competitive advantage for his com-pany group. The count sees the use of thatadvantage as a true challenge facing him,the seventh generation. The slogan: Thetruly new can only be built when history ishonored.

Back to business: In the clinic department,the group has set its sights on sales of 55million euros. In the baths department, thecompany has currently invested 20 millioneuros into the renovation of the park hoteland an expansion of the wellness area.Planned future sales: 10 million euros annu-ally. The spring water department, includ-ing not only the Bad Driburger Natur-parkquellen but also the Harzer Kristall Brun-nen in Langelsheim (Lower Saxony), integratedinto the group since 1994, should alreadyreach that level of sales in 2006.

PIONEER IN 0.75-LITER REFILLABLE

GDB PET BOTTLE FOR SOFT DRINKS...

The well-tested as a basis for the new. Well-tested – for Count Marcus, that is the qual-ity of the mineral water, which is derivedfrom its balanced, harmonic mineralizationand low sodium content. New – that is thestep to modern styles of packaging. That

THE TASK Integrate new packing and

labeling system for refillable PET bottles

into an existing glass line.

THE SOLUTION

• Packing technology with unique

format part changing system,

modular principle, and a special

packing head.

• Labeling technology with two

stations, VarioDrive, and four cam-

era systems.

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The PerfectionistsBad Driburger Naturparkquellen: Refillable PET plus glass



began with the 0.75-liter GDB [Genossen-schaft Deutscher Brunnen] refillable PETbottle – for soft drinks. Martin Lehmann,CEO of Bad Driburger Naturparkquellen,reports: “We started using this format asone of the first German spring water oper-ations about a year ago, and offer our softdrinks Sport Aktiv, apple spritzer, and orangeand lemon soda pop in these bottles. Today,50 percent of our soft drinks are sold tothe consumer bottled in PET.”

... AND NOW THE 1.0-LITER REFILLABLE

PET BOTTLE FOR MINERAL WATER...

Similar successes can also be expected formineral water bottled in PET. Since early2006, the Bad Driburger Naturparkquellenhave relied on a custom-designed 1.0-literrefillable PET bottle for mineral water, whichhas succeeded in fulfilling the expectationsof a premium brand – using targeted differ-entiation and selective attractiveness. The

path to the refillable PET was planned to thesmallest detail. Because the decision forthe plastic bottle was made upon comple-tion of market research.

The refillable PET bottle for mineralwater has an appropriately classical elegantdesign and a slender bottle shape. The con-nection between the familiar appearance ofglass with that of the new PET bottle is dueamong other things to the aluminum cap,the champagne bottle type base, and PET’ssimilarity to glass. Added to this: the so-called ‘toasting f igures’ shown on BadDriburger glass bottles. It is conspicuouslyintegrated as a motif.

... AND ALSO RETURNABLE PET CRATES

Since every bottle needs a matching crate– as the people in Bad Driburg well know –the returnable PET crate had to be some-thing very special. So that the consumercan recognize the Bad Driburger brand atthe point of sale even from a great distance,the individual crate has a cutout on eachside allowing a full view of the bottles.

The bottles are then positioned in thecrate in such a way so that the label commu-nicates directly with the consumer. The Bad

Driburg logo is also everywhere on the crate– even on the carrying handle that has beendesigned as a novel lengthwise soft-touchgrip. In addition, the bottles are arrangedin a circle around the carrying handle givingit another unusual visual impression.

One can imagine just how much clevertechnology is behind all that. The countexplains: “We spoke with many providers ofmodern filling and packaging systems. Manyof them told us it would be impossible tofulfill these requirements. But not KHS,here we felt understood and supported rightfrom the start. In KHS, we are dealing withan innovative company who gets involve incustomer desires and isn’t afraid of new chal-lenges.”

A LINE FOR ALL EVENTUALITIES

This task is as follows: Integration of newpackaging and labeling technology into anexisting glass line in order to equip it foradditional refillable PET bottle handling.And the capacity must be adapted to thefiller output of 22,000 1.0-liter bottles perhour. The filler – how could it be otherwise– is from KHS. Lehmann says, “This fillerhas excellent performance – another argu-

* Family company in the seventh generation

* Business areas: springs, baths, clinics

* Naturparkquellen: 30 million bottles per year, ofwhich: 50% mineral water, 20% healing water, 30%soft drinks

* Mineral water: 50% Bad Driburger Classic, 30%Medium, 20% non-carbonated

* Soft drinks (50% in PET): Sport Aktiv (50%), ACEStill, orange soda pop, and apple spritzer

THUMBNAIL PORTRAIT: BAD DRIBURGER2

Left Crater and decrater at Bad Driburger: Innopack SP times two. Right Implemented for the first time

worldwide: The new, nearly fully automatic, space-saving KHS format changing system.


ment for the user of KHS technology for thisproject.”

THE DESIRES OF THE CUSTOMER, PER-

FECTLY FULFILLED

Both the crater and the decrater are InnopackSP two-axis machines of the newest gener-ation with the innovative KHS dry area mod-ule concept. Both are equipped with ground-breaking KHS innovation: the KHS format

changing system. Bad Driburger is amongthe first companies in the world to imple-ment this innovation.

A special feature of the format

changing system:

* The complete packing set is changed atthe press of a button at the operatorpanel.

* A few manual activities still needed:Compressed air hose and electrical con-nectors must be disconnected from theprevious packing set and connected tothe newly installed one.

* Work that takes only a few seconds.* The system picks up the gripper heads,

centering frames, and lane plates oneafter the other, parks them, and thenpicks up the required new componentsto install them on the crater – all fullyautomatically.

* Extremely space-saving solution allow-ing a number of packing sets.

The special features of the

packing head:

* A sensor ensures perfect PET bottlealignment in the crates.

* Using luminescence detection, the sen-sor locates special printing marks onthe labels of the bottles, which areinvisible to the human eye.

* Quick, accurate turning of the bottlesis then performed based on the print-ing mark information.

* The bottles are also – and this isanother challenge, which the packerhead satisfies perfectly – oriented insuch a way that they are actually inter-laced in the crate. This results in thedesired circular positioning around thehandle.

Plant Manager Lehmann comments: “Weknow our special needs. That’s why were

even happier that KHS satisfied our plansperfectly – even with regard to labeling.”

The labeling of the challenging 1.0-liter refillable PET bottles and the varioustypes of glass bottle is handled by the InnoketRoland 24/6. It processes up to 28,000 bot-tles per hour using the wet glue labelingtechnique. There are two labeling stationsto apply back and front/neck labels.

Special features of the labeler:

* Maximum flexibility using the Vario-Drive electronic bottle turret controlsystem.

* The bottle turret, motor, and electronicequipment form a single unit and com-municate directly with one another.

* Four camera systems, each coupledwith a lighting unit, ensure exact labelapplication.

* A computer algorithm evaluates con-trast differences, comparing the actualand expected states of the toasting fig-ure. A bus system then communicatesindividual correction rotations directlyto each VarioDrive, which executes themprecisely. The result: the circular cut-out in the neck label precisely surroundsthe toasting figure. At the same time,the lettering on the front label isaligned with the center of the toastingfigure, along with the correspondinglyperfect application of the back label.

This is how KHS uses the latest in technicalsolutions to provide perfection down to thelast detail. Marcus Count von Oeynhausen-Sierstorpff and Martin Lehmann agree. Justas they agree on how convinced they arethat the success story of their company willcontinue.

Günter Unkrig, Director, Central European Region,

KHS AG, Dortmund

Frank Schneidermann, Sales Germany,

KHS AG, Dortmund

• WEBSIDE www.bad-driburger.de• CONTACT

Günter Unkrig, Director, Central EuropeanRegion, KHS AG, DortmundTel: +49 (231) 569-1602E-mail: [email protected] Schneidermann, Sales Germany, KHS AG, DortmundTel: +49 (231) 569-1104E-mail: [email protected]

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Labeling perfection: The circular cut-out in the neck label precisely surrounds the emblem

of the so-called toasting figure, the lettering on the front label is centered, and the back label is

perfectly and securely seated.


48*49

Why not come right to the point? The new KHS bottlewasher Innoclean SEC provides the best cleaning results,ecological and cost advantages, is extremely compact,and can easily be integrated into existing systems. Atthe same time, it sparkles with all the technical high-lights from the area of KHS high-performance bottlewashing technology. In short: High-tech from the finestfor the midsized beverage industry.

The Innoclean SEC is specially designed for thecleaning of glass bottles at a capacity of 6,000 to 24,000bottles per hour. The bottle sizes and shapes can vary:Everything is doable, from 0.2-liter to 1-liter bottles –in the brewing industry or in companies in the fruit juice,wine, dairy, and soft drink industries. This machine issmall, but it’s multitalented.

TWELVE HIGHLIGHTS: ENORMOUS ADVANTAGES

IN THE FIELD The system also offers some highlightsthat will bring you significant advantages in practicalapplication. A quick overview:

Triple-i-Drive integrated. Synchronous cyclesfor all drives without mechanical connection /

mechanisms are decoupled / intelligent control / fastdata transfer and exchange with servo converters indrives / gentler movements / lower replacement partand maintenance costs / preventive maintenance / push-button conversion when switching bottle types / man-ual transfer to bottle discharge eliminated for productchangeover / short reconfiguration times – all withoutstopping the cleaning process.

technology+innovation °

1

Left Compact Innoclean SEC single-end bottle washer:

Specialized in the washing of glass bottles at an output of

6,000 to 24,000 bottles per hour.

The new Innoclean SEC is a gem with twelve impressive advantages

High-Tech at Its Finest

The new Innoclean SEC bottle washer is the KHS team’s great success for the smaller capacity systems ranging from 6,000 to 24,000 bottles per hour. And three times over, too: technologically,economically, ecologically – for beer, fruit juice, wine, and even dairy and soft drinks.


Energy-saving bottle carriers standard.

In comparison with traditional steel carriers, theenergy-saving carriers use up to 15 percent less heat,as well as up to 20 percent less water / Weight reduc-tion between 20 and 25 percent / Full load still sup-ported.

Pre-soaking and pre-spraying standard.

First residue removal, then pre-soaking / Pre-heating of the bottles / Soaking of dried-on beverageresidue (e.g. fruit fiber, yeast residue) / Complete fill-ing of bottles / Removal of beverage residue even beforethe caustic treatment. Pre-spraying removes (drinkingstraws, cigarette butts, lemon slices, etc.) from the bot-

tles / Jetting is always a combination of Triple-I-Drivewith classical full-stream spraying – pressure of thespray jet shooting vertically into the bottle alwaysremains constant.

New Drivejet spray.

New type of spray combining Triple-i-Drive withclassical full-stream spraying – the pressure of the sprayjet shooting vertically into the bottle always remainsconstant – bottle speed slowed while spray directed intothe bottle – speeds up when spraying between bottles.

High label removal rate.

In the caustic bath, calculated flow in combina-tion with submerged caustic flushing / Immediate removalof labels loosened earlier / Pulping of the label papereffectively reduced / Upper caustic flushing removesremaining labels / Outstanding label removal rate (com-parable to high-performance range)

Minimum caustic carryover.

Peak value / For 0.5-liter bottles, about 8 milli-liters per bottle / Up to 25% lower cleaning agentconsumption.

Optional full stainless steel version.

Optional stainless steel caustic (interesting forsingle-shift operation or daily processing companies)

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• WEBSIDE www.khs.com• CONTACT

Bernd Molitor, Competence Center Manager, Cleaning Technology, KHS AG, DortmundTel: +49 (231) 569-1573E-mail: [email protected] Nielebock, Product Manager of the Cleaning Technology Competence Center, KHS AG, DortmundTel: +49 (231) 569-1340E-mail: [email protected]

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The new Innoclean SEC

C C


/ With stainless steel, no corrosion problems caused byresidual water / Long life.

Heat exchanger saves energy.

External heat exchangers redesigned for heatingof caustic bath / Plate heat exchanger ensures optimumheat transmission / Regulation of condensate sideincreases efficiency of steam use / Power consumptionreduced by up to 5 percent / Furthers compact design.

Compact design.

All functional components (for instance, drives,pipelines and pumps, filters) on machine side only / Forsmaller spaces, higher machine performance with samebottle handling time / Equipment standardized / Fourwidths and two lengths available / Machine is one piececomplete with piping and wiring; tested.

Fresh water consumption minimized.

After caustic bath, recooling of bottles and rins-ing of cleaning caustic from bottles and carriers / Fourspray zones standard / Full-stream spray with variable-cycle drive speed.

Special feature: fresh water spray stops once thebottle leaves the spray stream – this keeps the consump-tion of fresh water as low as possible / Energy-saving bot-tle carrier ensures good washing behavior with minimumwater consumption and low heat carryover / Maximum of

160 ml of fresh water per 0.5-liter bottle – an excellentvalue for this performance range. Cascading water circu-lation, just as in high-performance range / only one pumpsize (standard until now: up to three different pumps).

Maximum microbiological safety.

As for KHS high-performance cleaning, the micro-biologically unsafe condensation of vapors on cold exte-rior surfaces of the discharge is prevented by heatingthe critical media surfaces / Also integrated: vaporexhaust (avoids the suction of contaminated air intothe machine head section) / No danger of biologicalreinfection of cleaned bottles.

Easy and straightforward operating.

Operation using color monitor / Major functionsare automated / Plug-and-play startup / Manual sani-tizing.

Result

Considering all aspects – the focus of all technologiesMade by KHS is always on customer benefit.

The first machine is sold to Herbsthäuser BrauereiBad Mergentheim.

Bernd Molitor, Competence Center Manager,

Cleaning Technology, KHS AG, Dortmund

Jan-Karl Nielebock, Product Manager of the

Cleaning Technology Competence Center, KHS AG, Dortmund

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Left Bottle speed low, fresh water active, long-term

full-stream jetting into the bottle.

Middle Bottle speed high, fresh water inactive, external

bottle jetting in the recooling zones.

Right Bottle speed high, fresh water inactive, optimum

spraying of the energy-saving carrier.

50*51technology+innovation ° The new Innoclean SEC

C


Technical terms in practice

From the outside, there is nothing to be seen – but inside they are extremely complex: Modern filter sys-tems improve the beer product for the consumer. KHS is in on it right from the beginning with its filtrationtechnology. A brief excursion through the increasingly rapid development of beer filtration by Dr.-Ing.Hartmut Evers, college lecturer and Manager of the Laboratory and Technology Center at KHS.

The exact date that beer filtration started cannot be determined.However, it can be justifiably maintained that the development ofmodern filtration technology began in June 1878 with the inven-tion of the universal fast filter by Lorenz Albert Enzinger. The spe-cial feature of this filter was the use of ready-pressed filter sheetsfor the first time.

Filtration is the last stage in the beer making process beforethe beer is bottled and sold. The effect achieved by natural clari-fication is improved primarily with the help of filtration in order tobe able to offer the consumer a bright, clear, and non-perishablebeer. With filtration, this task not only requires the exact knowl-edge of all determining factors, but also the exact control of thefiltration process. But filtration must also be optimum for eco-nomic reasons.

THE PRINCIPLE

Beer filtration involves the separation of liquid and solids. Theproblem is one of a liquid flowing through porous bodies. Here,the filter cake holds back the substances that cause turbidity. Thisoccurs predominantly due to a straining action, but also partiallydue to adhesion and/or adsorption – depending upon the compo-sition of the filter aid. In filtration especially, the clarified phase

is called the filtrate and the solid material separating onto the sup-port sheet is called the filter cake.

THE FILTER EQUATION

Ideal cake filtration can be described using Darcy’s equation. Strictlyspeaking, this only applies to laminar flow through a porous, incom-pressible filter cake and states that the volume flow is proportionalto the pressure difference p applied between the top and bottomside of the filter and is inversely proportional to the dynamic vis-cosity of the filtered liquid . The higher the applied pressure dif-ference and the lower the viscosity, the higher the filtration vol-ume flow per unit area. Furthermore, a factor described as the fil-tration resistance R is included in the equation. The higher thisresistance, which opposes the liquid flowing through the porouscake, the less filtrate is produced per unit time and unit area. Inturn, the filtration resistance R is made up of the cake resistancerk and the resistance of the support sheet ro.

Filtration: Makes Perfect

1 2 R = rk + ro


PRECOAT FILTRATION

Filter medium is applied to a highly permeable support layer (metalsieve, filter cartridge, cellulose support sheet). The surface is con-tinuously renewed by dosing permanently with kieselguhr. Thereis significant scope for controlling the filtration depth through theselection of filter aids with different degrees of fineness. The fil-tration duration can be influenced by using different amounts ofkieselguhr. Kieselguhr is the main filter aid used, but Perlite, a spe-cially conditioned ground volcanic rock, is also used.

An alternative method of precoating, dosing and preparingthe kieselguhr mixture is often necessary.

KHS has the right filter for every application: The Getra Ecois provided as a cartridge filter for pre-clarification of products. Ifstabilization is required, a horizontal mesh filter, the Kosmos, canalso be used in addition to the Getra Eco. A kieselguhr frame fil-ter in the Orion range has proved its worth in thousands of ways.Post-filters are also available. These are known as Corvus and areranked with the group of fine filters and membrane filters.

The latest knowledge is leading to kieselguhr-free filtrationwith cellulose mixtures as used by KHS in the new KOMETRONIC fil-ter system.

Here, the filtration principle is as in any precoat filtrationand can be seen in the diagram on Page 54.* A precoat is first applied to a stainless steel support mesh.

Here, the so-called building of bridges is of great importanceand gives the built-up layer its strength.

* In the next step, a finer filter aid is applied, thus building upthe filter cake.

* When precoating is complete, the actual beer filtration beginswith the continuous dosing of the filter aid to the cloudy unfil-tered product.

52*53technology+innovation °

• WEBSIDE www.khs.com• CONTACT

Dr.-Ing Hartmut Evers, Laboratory and Technology Center Manager, KHS AG, Bad KreuznachTel: +49 (671) 852–2252E-mail: [email protected]

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* The relatively large yeast cells can sometimes act as a positivefilter aid when building up the filter cake. If the amount ofyeast is too great, however, this has a negative effect andblocks the filter cake.

THE FILTER MODELS AND COMBINATIONS

The oldest, but even today still most widely used, precoat filtersare frame filters (ORION) with frame sizes between 40 x 40 cm and120 x 120 cm. The work involved in removing the kieselguhr andin cleaning is relatively high; rinsing, sterilization and precoatingcan however be automated.

Bowl filters such as are used in the Getra Eco are more suit-able for automation. These filters have an hourly capacity of 5hl/h·m2,although due to the higher load per square meter, their service lifeis lower than that of frame filters. After precoating, however, bowlscan be purged with carbon dioxide thus reducing the beer loss andundesirable mixing with water. Kieselguhr is removed automati-cally by spin-off, high-pressure spraying or blasts of air. The result:Despite shorter service life, due to lower set-up times and the fact


that they can be fully automated, bowl filters are more economicalthan filter presses. The used kieselguhr is discharged as a thickpaste or in semi-solid form, reducing wastewater contamination.

The latest filter system is the KOMETRONIC with horizontalfilter elements and central infeed. This filter has many special fea-tures and these are only listed briefly here. A special presentationof the filter will be provided in a later issue.

ADVANTAGES AND SPECIAL FEATURES OF THE KOMETRONIC

* Optimized, specific flow control during all processing steps –particularly during cleaning and precoating

* Individually controllable filter elements for all process methods* Control of any filter area* Closed system* Reliable separation between filtrate and unfiltered product* Static filter system, therefore no moving parts for filter san-

itizing* Regeneration of filter medium

* Significant savings in operating costs* Low maintenance costs and easy servicing

SUMMARY

Kieselguhr filtration has enjoyed great success in Germany since1950. Kieselguhr was used for the first time in England from themiddle of the 1930s, initially as an additive to the mass. Actualkieselguhr filtration for beer developed in the U.S.A., from whereit came to Europe. However, disposal has become a major problemin past years. As a result of rapid cost increases in the disposal sec-tor, fees of up to 500 euros per ton of wet kieselguhr are no longera rarity at special waste disposal centers. This developing trendhas triggered activities in various directions. These relate to theconditioning of used kieselguhr using presses, drying, heating, andsifting or by treating with caustic and acid. Other research is con-cerned with the abandonment of kieselguhr as a filter aid.

In the search for ways of replacing kieselguhr, a return wasmade at the end of the 1990s to the regeneratable filter mass. Thisresulted in the development of a new filtration principle, whichbrings advantages by combining the clarifying filtration and sta-bilization sections to form one process step with complete regen-eration of the filter aid. This development was an inducement forKHS to adjust to the new circumstances, and to further enhanceand market the filter system that had already been developed inthe 1980s, which at that time was distributed under the name Komet.

Priv.-Doz. Dr.-Ing. Hartmut Evers, Laboratory and

Technology Center Manager, KHS AG, Bad Kreuznach

Size relationships between yeast, bacteria, kieselguhr,

and the support sheet

Bridge building in cake-forming filtration,

precoating, and dosage

Filter cake build-up

Filter, textile,

sieve, or cartridge Pre-coating with kieselguhr Filtrate

FiltrateFilter cake with dosing

Bacteria: 1-4 μm

Yeast: 1-5 μm

Kieselguhr:

Fine 2-10 μm

Medium 10-20 μm

Coarse 20-40 μm

Filter sieve: 25-55 μm

Technical terms in practice


The BRAU Beviale in Nuremberg has developed into an internationaltrade fair and KHS welcomed customers from all over the worldagain this year. We hope you were among them.

If not, perhaps you’ll have the opportunity of getting toknow the city of Nuremberg better the next time or during your nextvisit to Germany. Nuremberg is famous for its cultural assets, thetown center lying within the old town walls with its historicalchurches, squares, memorials and the 11th-century Kaiserburg tow-ering over everything.

Should you ever have the chance to tour this beautiful cityon your own, it is best to start your tour opposite the NurembergCentral Train Station with the Tradesman’s Court and its antiqueworkshops nested in among 12th century pubs. From here, gotowards the central market via the Breite Gasse shopping avenueto the Ehebrunnen, then past the Church of St. Lorenz (built in1274) over the leisurely flowing Pegnitz to the Church of Our Lady.From the bridge, you can see the Heilig-Geist-Spital jutting intothe river.

The Schöner Brunnen with its wishing ring stands in the cen-tral market place with the Church of Our Lady, where the Christmasmarket begins on the first day of Advent. Turn the ring, and yourwishes will come true. I hope so, at any rate. But now it’s high timefor a little snack. If you are hungry for an original NurembergBratwurst, you should visit the largest restaurant of its kind in theworld, the Bratwurst Röslein.

Or walk another 100 meters past the St. Sebaldus Churchdating back to the year 1230, across Albrecht-Dürer-Platz – andyou will find yourself in the middle of the castle quarter. Herestands the Gasthaus Schlenkerla by Albrecht Dürer’s House withits world-famous Rauchbier. King Juan Carlos, soccer star ‘Kaiser’

Franz Beckenbauer, and also commoners such as Helmut Kohl,Dietrich Genscher, and Jacques Chirac have dined only a few metersfurther in the Sudhaus.My special tips in the castle quarter are the Alte Küch’n (in exis-tence for 400 years) and the Rittersaal-Keller in the Burghotel.Here, you will be spoiled with Franconian specialties and the flairof the surroundings. Anyone just wanting something to drinkshould seek out the little bars and pubs below the castle. And onthe way back to the hotel, a small nightcap in the Kon-Tiki or theZauberberg is almost a must.

Hope to see you soon in Nuremberg!Georg Herrmann, Senior Installation Inspector, KHS AG

NurembergWelcome to

Left Kaiserburg with Albrecht Dürer’s House: Rauchbier [smokebeer] can be

obtained right next door in the Gasthaus Schlenkerla Top The Church of Our

Lady with the ‘Schöner Brunnen’ [Beautiful Fountain] in the foreground. Turn

the ring – and wishes will come true.

Tradesman’s Court: 12th century workshops and pubs

54*55Guest at KHS °


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AboutPUBLISHER

KHS AG, Dortmund

EDITORS

Friederike Arndt, Maternus Gemmel, Manfred Rückstein, jj-media, Cologne

GRAFIK

Konzeption+Design, Trawny / Quass von Deyen, CologneLayout: Nicole Bock

CONTRIBUTIONS

Wolfgang Augel, Nenad Delovski, Priv.-Doz. Dr.-Ing. Hartmut Evers, Meinhard Fischer,Andreas Flora-Asendorf, Volker Geng, Georg Herrmann,Manfred Keller, Erhard Magin, Bernd Molitor, Jan-Karl Nielebock, Michael Schlegel, Frank Schneidermann, Manfred Seifert, Günter Unkrig

TRANSLATIONS

Fachübersetzungen CP MacKusick

PHOTOS/ILLUSTRATIONS

Friederike Arndt, Hermann Dornhege,Einsiedler Brauhaus GmbH, gettyimages/

Charles Bowman, Hans Gronauer, Tobias Gursch,Fotostudio Koechlin, 2000 Michael Peuckert/Agentur,Pixelquelle, Stadt Nürnberg,Stieglbrauerei zu Salzburg GmbH,vario images/Christian Ringbaek,Unternehmensverbund Karlsberg

KHS journal offers young students and graduates of theUniversity of Applied Sciences in Dortmund and Münsterthe opportunity to put their photography talents intopractice.

This information is non-binding. Only the technical specifications of our quotes are determinativewith regard to design and scope of delivery.Subject to design modifications.

AdressesKHS AG

Juchostrasse 20D-44143 Dortmund, GermanyTel +49 (231) 569-0Fax +49 (231) 569-1541

Planiger Strasse 139-147D-55543 Bad Kreuznach, GermanyTel +49 (671) 852-0Fax +49 (671) 852-2411

Enzingerstrasse 139D-67551 Worms, GermanyTel +49 (6247) 97-0Fax +49 (6247) 97-3215

Ruwoldtweg 14D-22309 Hamburg, GermanyTel +49 (40) 63703-37100Fax +49 (40) 63703-37150

Boschstrasse 1-3D-47533 Kleve, GermanyTel +49 (2821) 503-0Fax +49 (2821) 26110

Am Kirchfeld 3D-34454 Bad Arolsen, GermanyTel +49 (5691) 8909-0Fax +49 (5691) 8909-15

Kapellenstrasse 47-49D-65830 Kriftel, GermanyTel +49 (6192) 491-0Fax +49 (6192) 491-144

E-mail: [email protected]

KHS METEC GMBH

Industriegebiet Scheid 16D-56651 Niederzissen, GermanyTel +49 (2636) 9746-0Fax +49 (2636) 9746-45E-mail: [email protected]

KHS UK LTD.

Unit 6 Monkspath Business Park,Highlands Road Shirley Solihull, Great BritainWest Midlands B 90 4NYTel +44 (121) 713-6901Fax +44 (121) 745-5306E-mail: [email protected]

KHS USA, INC.

880 Bahcall CourtWaukesha, WI 53186, U.S.A.Tel +1 (262) 797-7200Fax +1 (262) 797-0025E-mail: [email protected]

5501 N. Washington Blvd.Sarasota, FL 34243, U.S.A. Tel +1 (941) 359-4000Fax +1 (941) 359-4043E-mail: [email protected]

KHS PACIFIC PTY. LTD.

P.O. Box 3781-3 Freight RoadTullamarine, Vic. 3043, AustraliaTel +61 (393) 35-1211Fax +61 (393) 35-1331E-mail: [email protected]

KHS ASIA PTE. LTD.

25 International Business Park# 3-15/19 German CentreSingapore 609916Tel +65 6560-9313Fax +65 6560-9910E-mail: [email protected]

KHS worldwide: You will find further addresses and contacts at

www.khs.com


KHS Journal 04_06 e

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