KHS journal

Fruvita: Innovative ACF for juices

4 2006

English

The Fruit King

KHS Innoclean SEC: Smaller units score big

High-Tech at Its Finest

Sinalco: Keg line assists meteoric growth

A Brand Returns

KHS IN CHINA

+ Majority interest in GLM2 + Six leading companies order cutting-edge KHS technology + Successful at China Brew & Beverage + Landmark brewers seminar in Wuhan

Milestone in Internationalization

editorial

KHS AS A GLOBAL PLAYER BENEFITS FOR GLOBALLY ACTIVE CUSTOMERS

Maternus Gemmel, Chief Sales Officer KHS

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, I literally saw it happening little by little. For example, not all that long ago my trips between countries and continents involved extensive 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 have become much shorter. In addition, globalization is a catchphrase on all continents, leading to cultural and interest spheres growing closer together. Globalization represents a tangible and experiencable spirit of our age. We are all turning into cosmopolitans, while of course retaining special local characteristics. Global human development sets the parameters for the companies on our globe. The degree to which companies can be successful depends on the degree to which they are prepared to respond to their customers. Beverage, 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, over the years it has in fact become a worldwide company and acts accordingly on a daily basis. This means wherever our customers intend to 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 have achieved comprehensive local production presence with six plants in North, Central and South America, India, and now also China, plus our locations in Germany. Our motto: We are always there when you need us, wherever you are in the world or wherever in the world you will be in future. We want to affirm our vision of KHS as a global market leader and preferred supplier for the packaging industry with 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 local know-how where required. This is the basis for mutually successful partnerships. Our one face to the customer concept underlines our focus on customer orientation. Do you remember the traditional Latin phrase nomen est omen (true to its name)? Im deliberately referring to long-standing and welltried tradition, because without it and without reliance on what has been tried and tested neither globalization nor the future as a whole will be possible. This saying is therefore part of the tradition that KHS has preserved. The name KHS can be interpreted as Knowhow, High-tech, Service. In the past, today and in future. It includes a commitment to global presence and here weve come full circle and gives you assurance that you have a supplier as a reliable partner who has the ideal prerequisites for accompanying you into a successful global future. Yours truly

We at KHS, support our globally active customers

as partners in every respect.

contents 42006

02*03

people+markets 04 10
news Customers, Know-how, and Contacts

04

KHS 2010 plus 14

Interview with Volker Till, KHS Chief Technical Officer Standards Benefit the Customer

dialog+opinion 16
Interview with Bernd A. Diederichs, NrnbergMesse From a National to a European Family (Af)Fair

16

task+solution 20 25 28 30 34 37 40 42 46
Fruvita in Serbia relies successfully on ACF with dry sterilization The Fruit King Winzer Krems: Austrias largest viticultural cooperative has a tradition of innovation The Keg Wine Pioneers Jazak Mineral Water, Serbia: The slightly different success story Perfect Connection The success story of the Stiegl Brewery, Salzburg, goes merrily on Record in Mozart Year Voda Voda: Unique overall concept Water to the Power of Two Saudi Arabias Pepsi bottler with high-performance canning lines Sipco Sets an Example Pepsi-Cola, Iraq: Licensing partners placing trust in KHS equipment 6 Lines in 2 Years KHS keg technology involved in the global comeback of Sinalco A Brand Returns Bad Driburger Naturparkquellen: Refillable PET plus glass The Perfectionist

20

34

42

technology+innovation 49 52 55
The new Innoclean SEC is a gem with twelve impressive advantages High-Tech at Its Finest Technical terms in practice Filtration Makes Beer Perfect

Guest at KHS
Welcome to Nuremberg

55

 Majority participation in Chinese bottling and packaging specialist The company acquired is among the market leaders in China GLOBAL STRATEGY Markets for bottling and packaging machines are growing in the double digits

KHS GOES CHINA

KHS AG is strengthening its presence in China and in Asia by taking over majority control of the Chinese company Guangdong Light Industrial Machinery Plant 2 Ltd (GLM2). As a manufacturer of filling and packing equipment, with headquarters in Shantou in the province of Guangdong, the company is positioned excellently in the Chinese and Asian market. With a sales volume of more than 30 million euros, GLM2 is one of the market leaders in the industry in China and is building an extensive network in China and Asia. GLM2s list of customers includes big names in the brewing trade such as Tsingtao, C.R.B., Yanjing, Kingway, Harbin, Asian Pacific, San Miguel, Chonqing, Lion, Jingxing, Heineken, and AnheuserBusch. By acquiring GLM2, KHS once again points the way to the future in the Asian market. Just recently, KHS increased its share in the Indo-German joint venture KHS Machinery Pvt. Ltd. to 89%.

In addition, construction of a new KHS plant in India is soon to be completed. The contracts in China were signed by the partners on August 17, 2006. The former private owners sold their 70-percent share of GLM2 to KHS. Equal shares of the remaining 30 percent remain in the hands of the two managing owners, who will continue to be members of the company management. The transaction is expected to be concluded within the next few months after the required government approvals have been obtained. The significance of this agreement for all involved is underscored by Zheng Jiannong, managing owner of GLM2: For GLM2, the close partnership with KHS represents a milestone in the development of the company and opens up tremendous opportunities for both partners in Asian growth markets, particularly in China.

people+markets news

04*05

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).

SEMINAR AT WUHAN ACADEMY OF BREWING TECHNOLOGY

KHS LAUNCHES TRAINING FOR CHINESE BREWERS

Education is considered very important in China. That was the experience of KHS and the Wuhan Academy of Brewing Technology when they organized a prestigious brewing seminar from May 23 to 26 of this year. More than 100 participants from nearly all the breweries in China followed the presentations and lectures of the main speaker from the Technical University 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 event with talks by Ludwig Clsserath, head of the Process Engineering Competence center, and Dr. Hartmut Evers, head of Laboratories and Technology Centers. In the focus of their talks (all presentations to the delight of the public in the Chinese alphabet) was current research at KHS, from filtration to hygienic design, ultra-clean filling, beer in PET, to the latest in cleaning technology. The participants and the director of the Academy, Xu Gong Jin, experienced compelling presentations with many new discoveries, which will surely continue to contribute to forward-looking brewing technology in China. A concluding cruise on the Yangste River provided all the participants with the opportunity to experience the quality of Chinese beers.

The numbers confirm KHS steadily increasing participation in one of the most interesting growth markets in the world with the new investment in China. The demand for packaging machines for the beverage industry on the Chinese market alone will grow from about 390 million euros (2002) to around 900 million euros in the year 2010. The decisive point: 80% (2005) of this demand is covered by the domestic industry. The future need for modern technical solutions in the beverage industry is clarified by these figures: the yearly beer consumption in China is only 18.8 liters per capita. A high backlog demand is apparent and predicted. Experts in the beer sector expect that China will account for 50% of the worldwide increase 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 development of our international production network. The local presence continually called for by our global customers is now achieved by our plants in North and South America, India, and China in addition to our locations in Germany. We are convinced that with this acquisition we are now well prepared for the future globalization requirements in our branch of industry. With this move, we will continue to be one of the leaders of the market particularly in the growth region of Asia.

BALTIKA

NEW PET TREND: GLASS

Baltika Brewery, market leader in the Russian beer market, together with PET Engineering from Italy, is starting a new PET project: beer in PET bottles that look just as nice as beer in glass bottles. The Baltika3 quality PET bottle is designed to resemble the glass bottle shape, and also has the elegance of glass. It was also possible to improve the barrier properties.
At the opening of the new Sinalco production operation in Serbia (from left): Prime Minister Vojislav Kostunica, Vojin

HEINEKEN

SUCCESS RIGHT DOWN THE LINE

Heineken celebrated great success in the first half of 2006. Viewing each organically, sales rose by 6.3 percent to 5,738 million euros, net profit grew by 13.7 percent 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 volume climbed 11.6 percent (6.6 percent from an organic perspective) to 62.8 million hectoliters.

Djordjevic, owner of the Voda Voda (SI&SI) mineral water plant, and Maternus Gemmel, Chief Sales Officer of KHS AG.

SINALCO SERBIA: THE PRIME MINISTER ATTENDS THE OPENING

SINALCO TASTES GREAT ...

Five months after announcement of a joint venture between the SI&SI Group in Serbia and the German company Sinalco International, Sinalco Serbia opened its doors at the end of May 2006. The opening celebration of production operation in the Valjevo region (located next door to the SI&SI subsidiary Voda Voda, see page 34) was attended by anybody with a rank: ministers, dignitaries, representatives of the German Embassy and the Serbian Prime Minister Vojislav Kostunica, who in his entire political career had previously taken part in only five such ceremonies. KHS was also represented, by board of management member Maternus Gemmel among others. To the great satisfaction of the numerous inhabitants (and employees) who appeared from far and near, after the official opening by the Prime Minister there was the possibility of viewing both plants and the modern machinery.

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 the German nation team at the World Cup, the KHS Soccer Championship was held for the second time, with great success. The patron: Maternus Gemmel, Chief Sales 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 teams reflected international soccer fantasies such as Paraguay Labeling Friends, FC Dynamo Four-Wheeler, or Final Assembly Jgermeister guests and players alike anticipated a big day. From the live broadcast: At 11 AM was the starting whistle. The tension skyrocketed around the sports arena Auf dem Bleck in Dortmund-Asseln. During a playing time of 15 minutes each, the KHS teams battled it out to win the trophy the challenge cup. By late afternoon, the victor had been determined: The Elbcoast Kickers (1:0 against the Final Assembly Jgermeister) were celebrated by the enthusiastic crowd. A lot of fun. KHS CEO Valentin Reisgen, Maternus Gemmel, and Helmut Weber, Chairman of the Joint Works Council, were gratified by the successful event. They are all convinced: Next year, there may not be a World Cup, but there will be another KHS Championship.

U.S. MARKET FOR WATER COOLERS

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

people+markets news

06*07

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. After initial successes in the Saarland test market, this exclusive drink is now conquering the German market step by step. The Karlsberg Brewery and Amapharm have agreed to cooperate in marketing Karla. Until now, this company has specialized in the development and sales of nutritional supplements in fruit gummy form. Amapharm has both excellent national and international know-how in pharmacy marketing. No wonder that now more than 800 pharmacies 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 already great interest in Karla, Made in Saarland: Requests from the U.K., the U.S., and Japan are whetting the partners interest for international distribution.

CONSUMER POLL

WELLNESS DRINKS (II)

RUSSIA: JUICE FOR THE ELITE

The Lewada Zentr marketing research center has investigated the Russian market for juices in detail. The institute polled a total of 1800 people from 128 cities and 46 regions of the country regarding their consumer preferences. An important intermediate result: 60 percent prefer 100-percent juices. Whether a lot of juice is on the shopping list depends strongly on income. Under a wage of 4,000 rubles per month (100 rubles are about 3 euros) about 50 percent purchase juice products. At over 12,000 rubles, 90 percent buy juices, nectars, fruit wines, or fruit beverages. The most active purchasers, by the way, are aged between 18 and 39 years.

BOTTLES COMPOST WITHOUT RESIDUE

The pharmacy market chain Ihr Platz, represented by 728 locations throughout Germany, with a company tradition reaching back to 1895, is expanding its offering of organic and wellness drinks with a global first, according to company announcements. The company will carry Vitamore brand wellness drinks throughout Germany in the future packaged in fully compostable bottles. These are a special new development for Ihr Platz and consist entirely of polylactid (PLA). In contrast to PET, PLA is not made of petroleum but from corn, that is, a renewable raw material. The bottle cap is also made of a corn-based plastic. The PLA bottles are no different in appearance from traditional plastic bottles. In addition, says Ihr Platz, they are just as stable and can be stored nearly indefinitely.

RECORD OF SUCCESS

GEROLSTEINER: BOOM YEAR 2006

Gerolsteiner Brunnen the leading company in the German mineral water industry has recorded sales of 123.3 million euros in the first seven months of 2006. Thats a gain of 6.6 percent versus the previous 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 Gerolsteiner apple spritzer. According to market research institute AC Nielsen, the latter had the strongest growth, with an increase in value of 25.7 percent. The deciding share of the overall success were the latest in product innovations, Gerolsteiner Naturell plus Frucht, and Gerolsteiner Moment (both introduced to the market in May of 2006), along with Gerolsteiner Sport (on the market since June of 2006).

12 3

13 3

14 3

15 3

16 3

17 3

18 3

19 3

OPEN HOUSE

WELCOME TO KHS
With the slogan Open House at KHS, the KHS Group presented itself to employees and their families at its various locations in Germany. As a global leader in technology for filling and packaging for the beverage, food,

and nonfood industries, the company is very purposely making itself transparent to the public, presenting itself and its qualified employees, and introducing its products and services. For the specialists at KHS, a perfect opportunity to share their success with the community. The event series started in July at the KHS Bad Kreuznach plant and ended in October in Hamburg. And with extremely positive resonance: Visitors had the latest in filling and packaging technology explained, and were astonished by high-tech production systems and research facilities. KHS hands-on for the whole family.

BEER NEWS

HEALTH

BECKS PRODUCT ON THE OFFENSIVE

After the thoroughly successful innovations Becks Gold and Becks Green Lemon, Becks is bringing more interesting beer novelties to the German market. Becks Level 7 is a new refreshing energy mix with Guarana and an increased caffeine content. Becks Chilled Orange offers the special taste of kumquat, the winter orange, and a fruity-fresh aroma accompanied by pleasant sweetness. Both products have an alcohol content of 2.5 percent and are sold in transparent clear glass bottles.

BEER SUPPRESSES INFECTION

Once again, science has provided evidence showing that moderate beer consumption is beneficial to health. Researchers at the Medical University of Innsbruck demonstrated that some ingredients in beer have an infection-suppressing effect. More precisely: Beer extracts prevent biochemical processes, which release interferon gamma one of the most significant messengers for inflammatory response. According to the researchers discoveries, the metabolic processes positively influenced by beer extracts are closely related to the origins of chronic disease such as coronary illnesses.

people+markets news

08*09

GLOBAL GROWTH IN MILK PRODUCTION

MILK MAKES IT
Global milk production has grown noticeably in the past few years: From 384.8 million tons in 2001 to 414.9 million tons in 2005. Experts predict an additional growth of 2.7 percent in 2006. The largest milk producer is still the EU, with 132.3 million tons (2005). In second place is the U.S.A. (about 82.6 million tons in 2006) and India is in third place (about 39.5 million tons in 2006). Growth country number one in milk production is China. The Middle Kingdom increased production in 2006 by an estimated 20 percent with a production volume of 33.8 million tons. Thats fourth place, right after India.

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 mutual agreement (a memorandum of understanding), which includes a close cooperation of the two company groups in the design of filling systems. With the highest in best-practice standards, standardized filling technology should meet the requirements of CCSABCO in the medium and long term around the world, guaranteeing optimum shareholder return on investment. CCSABCO is active in seven African and five Asian countries, employs more than 9,500 people, bottles beverages at 26 bottling plants, and supplies about 240 million consumers through 450,000 trading partners. The companys vision: We will be the best Coca-Cola bottler in the world. The festive signing ceremony of the memorandum of understanding was attended by (left to right): the signatories Martin Jansen, CEO of the CCSABCO Group and Valentin Reisgen, CEO of KHS AG (seated), along with Maternus Gemmel, Chief Sales Officer of KHS AG, Martin Schrmann, Business Manager of KHS Southern Africa, and Erhard Magin, Director of Africa, Middle East, and Southern Europe Sales Region, KHS AG (standing).

FOSTERS ACQUIRED

SABMILLER INVESTS IN INDIA

SABMiller has acquired the bastion of Fosters in India for 120 million U.S. dollars. The number two company in the Indian brewery market intends to continue to push the success of Fosters Lager and to expand the brewery in the Indian state of Maharashtra (currently 350,000 hectoliters). Until now, India has been the largest international market for Fosters outside Australia.

FIRST WOMAN CEO AFTER 253 YEARS

WARSTEINER FAMILY TRADITION

Chatharina Cramer, daughter of the owner of Warsteiner Brewery, Albert Cramer, is continuing family tradition as the ninth generation, having taken the reins as managing partner and owner in the company group (Das einzig Wahre) comprised of 112 companies. The 28-year-old is the first woman heading the enterprise in the 253-year history of the brewery group.

KHS Around the Globe

CUSTOMERS, KNOW-HOW, AND CONTACTS

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

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

KHS IS A PARTNER IN THE MIDDLE KINGDOM

Ting Hsin International Group is one of the leading companies in China for food and beverages. The group has now ordered a turnkey ACF line for their operation in Tianjin, based on state-of-the-art KHS technology (dry sterilization). The ACF system is designed for a capacity of 48,000 500-milliliter PET bottles per hour and will go into production in the first half of 2007. Union Brewery Group in Beijing is innovating with the first PET bottle beer filling facilities in China. The group specializes in the production of beer, samshu, wine, and other alcoholic products, producing around four million hectoliters of beer annually. For its brewery in Beijing, the company has now ordered a PET line for beer from KHS. The line has an output of 20,000 440milliliter or 9,000 1,750-milliliter bottles per hour. Before filling, the system rinses all bottles with water (Innoclean EM 40) and then fills them volumetrically (Innofill DVF 60/10 SC). Due to the KHS extensive expertise in the field of PET filling, the brewery found the decision for KHS leading-edge technology very easy. Yanjing Brewery in Beijing is experiencing a strong surge in demand in the Chinese keg market. For one of the largest brewery groups in the country, thats a significant segment. KHS delivered and installed a complete keg washing and racking line for 120 (30-liter) kegs per hour. The system is equipped with an Innokeg Till TRANSOMAT 5/1 Duo, TRANSOMAT 5/1 Mono, exterior washer, keg turner, and a KHS Innopro flash pasteurizer. After the Yunnan Lancang River Group in Yunxian was successful with a KHS ACF filling line for green tea, there was no question about using KHS filling technology for the new brewery as well. At the end of this year, KHS is installing an Innofill DMG-SVF 84/12 CC along with the complete process technology including a CIP system and flash pasteurizer.

KHS is a partner in demand in China due to its high product quality, its excellent, customer-oriented service, and maximum flexibility, throughout a variety of industries in this booming country and will continue to expand its activities there in the future (see page 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 renowned beer using an Innofill DPG-ZMS 96/18 CC. Pepsi-Cola International continues to rely on KHS technology and service. Another installation, this one for Pepsi-Colas operation in Harbin, was just ordered by the company. The output capacity of this filling system will be 36,000 600-milliliter bottles per hour. However, the plant is also designed for the processing of 1.25-liter and 2-liter bottles. KHS is delivering an Innoclean EM 72 rinser, blocked with an Innofill DRV 108/18 volumetric filler. An Innopro CMX 36 Paramix unit will be responsible for the constant level of product quality. The Innopack Kisters SP 050 shrink packer will handle the task of packaging the filled products.

people+markets news

10*11

KENYA: RIFT VALLEY BOTTLERS / COASTAL BOTTLERS

REFILLABLE GLASS FOR COCA-COLA

The two Coca-Cola fillers Rift Valley Bottlers and Coastal Bottlers in Eldoret and Mombasa, Kenya, respectively, are each receiving a refillable glass bottle line with a capacity of up to 36,000 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 washer into the line. Both customers have relied for decades on quality and service Made by KHS. The new systems are also designed with the latest in technological advances, and above all are very easy to maintain. They are also prepared for subsequent integration of a labeler in case the customers would later like to switch from ACL to paper labels.

BREWERIES SUPPLY INTERNATIONAL (BSI), ST. PETERSBURG

BEAMISH & CRAWFORD

FLEXIBLE KEG LINE

Beamish & Crawford, a part of the Scottish & Newcastle Group, has ordered a new 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 Innokeg Till TRANSOMAT 5/1 Duo keg washing and racking systems. Special features: the ultra-modern AK6 external keg washer and the DFC filling system.

LARGEST KHS PET FILLER

Worlds largest KHS filler for plastic bottles ever manufactured is destined for Russia. BSI (Breweries Supply International) with headquarters in St. Petersburg ordered this world-record holder for BSIs Deka brewery plant in Veliky Novgorod. The dimensions of this bottling giant are 8.4 meters long, 7.3 meters wide, and 3.6 meters high, with a weight of about 30 tons. The system in Deka (36,000 2-liter PET 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 Russia as vodka, but has a very low maximum alcohol content of 1.5 percent. Innovator BSI started in Deka with kvas about two years ago. The company invested in a KHS turnkey line with a capacity of 18,000 2-liter PET bottles per hour. The new KHS Innofill DRV filler is equipped with 180 filling stations and is predestined for the filling of carbonated kvas. Magnetic-inductive flow measurement ensures exact filling volumes. Overfilling is not necessary. That saves product. When switching to a new bottle size, there is no more involved than the press of a button. Motto: maximum flexibility for all eventualities.

CUAUHTMOC-MOCTEZUMA BREWERYI

120,000-CPH CANNING LINE

The Mexican beer market is growing at an impressive rate. An investment decision oriented towards the companys future was made by the CuauhtmocMoctezuma Brewery in Orizaba, Vera Cruz, when they ordered a high-speed filling line from KHS for 120,000 cans per hour. That makes this line one of the groups largest in the southern part of the country.

MOSCOW BREWING COMPANY MYTISCHI

TRANSOMAT FOR MOSCOW

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

KARLSBERG BRAUEREI

PRIMO SCHINCARIOL INDUSTRIA

60,000-BPH REFILLABLE GLASS LINE 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, very successful with its Mixery brand beer mixed drinks, and is promoting canned beer exports, to France and other countries. KHS had previously received an order from Karlsberg for a new pasteurizer the existing two-year-old pasteurizer will now be relocated elsewhere. The new line (with a capacity of 60,000 0.5-liter bottles per hour) was particularly compelling due to its consumption figures and the technological data for the filling, capping, and bottle washing machines. For the processing of a variety of formats, the packing machines are equipped with automatic format changing systems.

BIGGEST KHS FILLER IN BRAZIL

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

HGL HACKLBERGER GETRNKE- UND LOGISTIKCENTER

INVESTMENT IN THE FUTURE

The HGL-Hacklberger Getrnke- und Logistikcenter GmbH in Hutthurm, Bavaria (parent company: Brauerei Hacklberg Passau) is investing extensively 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 capping machine, * KHS Innopro Paramix CMX 18-6/ T20 blending system with a connection for beer. The owner of Brauerei Hacklberg for many years has been Bischfliche Klerikalseminarstiftung St. Stephan of Passau. It is the largest brewery in the eastern Bavarian region with a full range of products.

FELDSCHLSSCHEN (CARLSBERG DEUTSCHLAND)

TRAY PACKER FOR NON-REFILLABLE PET

The Feldschlchen Brewery in Brunswick, Germany, a subsidiary of Carlsberg Deutschland, is taking delivery of an Innopack Kisters TP 50 B tray packer for 0.5-liter non-refillable PET bottles on 18-bottle or 24-bottle trays, including a pack conveying connection through a vertical diverter to the existing filling system.

OY HARTWALL, FINLAND (SCOTTISH & NEWCASTLE)

NEW: SPECIAL DOLLY PROCESSING

Finlands leading brewery, Oy Hartwall, has ordered a KHS palletizing center from KHS for a 52,000-cph canning facility in its Lathi plant in the south of the country. The company, a part of the British group Scottish & Newcastle, will use it to process multipacks, film-wrapped trays, and wrap-around cartons, which will in turn be placed on U-board trays. The innovation: 1/1, 1/2, or 1/4 Europallets and dollies with 600 x 400-millimeter dimensions can alternatively be used as packaging aids and carrier systems. KHS experts have developed a special palletizing solution for the first time for this purpose, along with a new conveyor system, which conveys either dollies or traditional pallets. The simultaneous processing of different packaging forms and materials is completely new.

EINSIEDLER BRAUHAUS

40.000-BPH FILLER FOR CHEMNITZ

The Einsiedler Brauhaus GmbH, a private brewery in Chemnitz, has ordered a KHS bottling machine for glass bottles. Output: 40,000 0.5-liter bottles per hour. Type: DRF 96/18 KK electronic long-tube filler that needs no vacuum pump, has excellent oxygen pickup values, and has a biologically optimized front table. The Einsiedler Brauhaus, with its particular special beers, is one of the largest private breweries in the new federal states, and is relying once more on its longtime partner KHS.

people+markets news

12*13

KIRIN BREWERY

ANNIVERSARY: 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 Brewery Company Ltd. The two recently ordered machines now up the count to 25. KHS is delivering an Innokeg Till CONTIKEG washer 32/30 and a CONTIKEG racker 20/18 with an output capacity of 1100 kegs per hour (7-, 15-, and 20-liter) to Kirins Kobe plant. For the first time, the new CONTIKEG generation is working with a Mitsubishi control system. The machines have as usual in Japan earthquake-proof cup-shaped feet. The washer is equipped with an automatic acid program to decalcify the cleaning heads (descaling). The filler has quick-changeover valves that shorten product changeover enormously, reducing product losses (product changeover without CIP caps). The filler is resistant to the rather aggressive cleaning and disinfecting agents used for foam application (external cleaning and disinfecting). Naturally, the outstanding DFC filling system is used in this filler as well. The two rotary keg washing and racking machines, which meet Kirins expectations in the latest of technological advances, will go into production in April of 2007 after only four weeks of installation and commissioning. Even in the late 1980s, Kirin was one of the first companies to rely on continuously rotating keg machines.

ASAHI BREWERIES

TOP PASTEURIZER FOR JAPAN

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

DAESUN DISTILLING

TROY AQUA

HIGH 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 completely new filling plant. In the future, several high-performance systems for the bottling of Soju should meet the demand for the local market. Daesun Distilling has just selected KHS for its first filling line. It has a capacity of 66,000 bottles per hour making it the first system to top the 60,000-bph mark in Korea and goes into production in April of 2007.

COMPLETE REFILLABLE PET TIMES TWO

The latest KHS Innofill filling technology will soon be on the job at Troy Aqua in Sittensen, an idyllic little town located between Hamburg and Bremen. The renowned specialist in the filling of generic brands has just ordered two complete non-refillable PET installations from KHS, each with a capacity of 26,000 1.5-liter bottles per hour. The ultra-modern lines are connected to the tried and tested Innopro Paramix, apply labels using Innoket high-tech hotmelt sheet-feed and roll-feed equipment. The KHS Innopack Kisters SP and CSM particularly stand out in the dry area along with a KHS Innopal PB palletizer. Both lines are monitored by KHS Innocheck inspection units. Troy Aqua has two newly drilled mineral water wells at its Sittensen location, has purchased a modern production plant located on a 40,000-squaremeter piece of property, and operates three shifts around the clock to meet the high market demand.

COCA-COLA ARCA GROUP

45,000-BPH REFILLABLE PET LINE

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

KHS renewal concept 2010 plus

Standards Benefit the Customer

Interview with Volker Till, KHS Chief Technical Officer
KHS-JOURNAL: KHS has announced that it will carry out even further product standardization as part of the change process. Where do you see advantages for the customer here? VOLKER TILL: Standardization will result in extensive unification. All standard or to put it another way identical products only have to be explained once, not only to the customer but also to our staff and service engineers. This way, we will be considerably faster and more efficient in the training of our globally active employees. Consequently, we are also able to provide better service. At the same time, we are able to manufacture our products at widely differing locations based on identical drawings. This saves shipping costs and what is often more important time, for in the case of sea freight, we are not talking in terms of days but of weeks. KHS-JOURNAL: What do you consider to be the most important aspects of product standardization at KHS? VOLKER TILL: The experience gained is further enhanced in tried-and-tested products. The same assemblies and parts enable us to produce faster and also more cost-effec-

KHS 2010plus

14*15

Our global alliance, an important strength of KHS, will benefit most from this.
tively. Our global alliance, an important strength of KHS, will benefit most from this. This will bring KHS even closer to its customers. KHS-JOURNAL: Will the standardization of control technology among other things play a decisive role? VOLKER TILL: The standardization of control engineering has always played an important role in the past. Standardization is basically also compliance with norms. DIN and ISO have long been extensively used in mechanical engineering. But standardization, particularly in the software area, is still in its infancy. Here, in many cases, individual engineering is still the order of the day. KHS is already making global standards for control and regulation technology available on the World Wide Web through the Engineering Portal. This service will be continuously expanded. KHS-JOURNAL: To what extent has product standardization already progressed? Do you have any idea when this might be complete or is it a permanently ongoing process? VOLKER TILL: Our products are modified to suit continuously 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 positive sense, of course. KHS-JOURNAL: As a turnkey supplier to the beverage, food, and nonfood sectors, KHS provides both packaging as well as filling equipment. Do different aspects apply in these areas with regard to product standardization? VOLKER TILL: The closer we get to the end of the production line, the more we find standardized processes and technologies. Virtually all products are palletized. Before this, most products are either packed in boxes or wrapped in film. Prior to these processes however, the majority of products are labeled, which shows that these production processes form the core technology of KHS. Now, the closer we come to the product itself, the more individual the technical solutions become. But standardization is also possible here. The best example is the turnkey lines we supplied to a well-known U.S. customer who fills liquid soap in PET containers using standard beverage fillers from KHS that required only a few very slight modifications to suit the field of application. The end packaging in this case is the usual KHS standard. KHS-JOURNAL: What about the consideration of individual customer requirements with KHS equipment in the future? Will it still then be possible to obtain system concepts that are exactly tailored to the respective company? VOLKER TILL: Naturally, standard cannot mean that we will offer only one type of filling valve. Standardization means arranging processes and technologies so that many requirements can be fulfilled with just a few different solutions. Furthermore, this is a significant advantage versus an individual solution that is manufactured only once. We can call upon proven technology. Prototypes and the related drawbacks for the customer testing them will become a thing of the past. Take the automobile industry as an example. In spite of standardization, no two cars will be the same on the assembly lines within the next two years. In exactly the same way, KHS customers will also receive machines and systems optimally tailored to their requirements as part of standardization. KHS-JOURNAL: Will the customary KHS quality also be guaranteed to the full extent in the future? VOLKER TILL: Standardization enables us to make better use of past experience and produce larger quantities. Parts, processes and also the people involved in adding value benefit from this. Everything is easier to understand and can be continuously improved due to the ongoing pedagogical benefits. What it boils down to is that standardization quite clearly improves quality. Mr. Till, thank you very much for this interview.

Getting together at BRAU Beviale

From a National to a European Family (Af)Fair

Interview with Bernd A. Diederichs, Managing Director of NrnbergMesse, held prior to the trade fair
Famous for Nuremberg Bratwurst, Nuremberg Lebkuchen, the Nuremberg Christmas market and popular attractions such as Albrecht Drers House, the Gnsemnnchenbrunnen [Goose Man Fountain], the Handwerkerhof [Tradesmens Court] and much more, the town of Nuremberg has something that other towns do not: that certain extra of coziness and an atmosphere of well-being. It remains to be seen whether the Nuremberg town feel radiates to the Nuremberg Trade Fair and thus the BRAU Beviale, the industrial gathering per se, or whether it is the unique exhibition concept, which has been thought out down to the last detail, that attracts the German and European beverage sector every year in November. Perhaps it is just the combination of these factors. For one thing is clear: BRAU Beviale has not only established itself as one of the leading European trade fairs for the beverage sector, but, at the same time, has become a family gathering of the European beverage industry. BRAU Beviale is all about getting together. Bernd A. Diederichs, Managing Director of NrnbergMesse, sees the BRAU Beviale fair as a European trade festival with heart. KHS journal in conversation with Bernd A. Diederichs, the man who actually wanted to become an architect and who now produces, establishes and what is certainly a significant factor manages and sustains successful exhibition concepts. BERND A. DIEDERICHS: In fact, it is very important never to lose sight of the roots of an exhibition. Such a strategy is often looked upon as being too traditional. In my opinion, a return to the roots and at the same time an establishment of innovative ideas thoroughly harmonize with one another. The BRAU exhibition established in Nuremberg in 1977 has thus changed from a national exhibition to a European trade fair, its name and activities have been expanded without renouncing its BRAU roots, and in spite of this has remained a family gathering. Instead of a small national family, it is today a large European family, and instead of a meeting of brewers, today it is a gathering of the whole beverage industry. Where in your opinion do the specific advantages of a family gathering 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 the communication between exhibitors and visitors and among the visitors themselves takes place automatically. Many visitors to BRAU Beviale feel that they have missed something if they do not attend the exhibition which, according to our exhibition surveys, can also have a negative effect on business. We therefore see an exceptionally constant frequency of visitors. This, in turn, is to the benefit of the exhibitors. Of course, as well as the family gathering aspect, we also see the success of BRAU Beviale in a high orientation towards innovation. The thing is to accommodate movements in the industry and to present innovations in the respective sectors. As an exhibition company, we use appropriate accompanying events to take into account the innovative character.

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?

dialog+opinion

16*17

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 Dsseldorf, 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 worlds leading trade fairs for consumer goods such as Premiere and Ambiente. Since 1997, Bernd Diederichs has been managing the NrnbergMesse, a company that today employs nearly 240 people and is one of the 15 largest exhibition sites in the world. The turnover of NrnbergMesse has almost tripled since 1997 to an expected 120 million euros in the 2006 financial year.

An exceptionally constant frequency of visitors can also mean that visitors are static and that new target groups of visitors are not really expected. What do you think of that with regard to BRAU Beviale? This is not at all the case. New visitors to BRAU Beviale are quickly integrated into the family. As indicated above all when BRAU Beviale changed from a national to a European event. The internationality of BRAU Beviale is continuously increasing. We also expect further growth in 2006. Thirty-eight percent of the exhibitors and twenty-seven percent of the visitors at BRAU Beviale 2004 were from abroad. The largest international presence was provided by Italy with 73 exhibitors ahead of Austria with 61, and the United Kingdom with 60. Substantial groups of visitors came from Austria, Switzerland, Belgium, the Czech Republic, and France as well as from the countries of the Middle East and Eastern Europe. We believe that these countries in particular still have an enormous potential. For example, if you look at beer consumption in the Middle East and Eastern Europe, growth rates of more than 47 percent have been realized here since 1999. At the same time, Russia, the Ukraine, and Poland represent the strongest growth markets. Of course, with all the well-meant euphoria, we are not closing our eyes to reality. Numerous mergers and company takeovers at on the German and European stage lead us to expect a consolidation of the number of exhibitors at a high level. We expect 1500 exhibitors in

2006 (1477 exhibitors in 2004). On the other hand, companies are naturally sending fewer employees to trade fairs than has previously been the case. The decisive factor is, however, that these company representatives generally have a very significant order budget. I predict that the number of trade visitors to BRAU Beviale 2006 will remain at about 37,000. Expertise and decision-making powers are increasing. Incidentally, 88 percent of all trade visitors to BRAU Beviale in 2004 were involved in purchasing and procurement decisions for their companies. Away from the number of visitors and exhibitors to the all-important factor visitor and exhibitor satisfaction. Of course, we carry out regular surveys in this area. In 2004, we received a clear Yes from 99 percent of visitors to the question of whether they were satisfied with the information and the contact opportunities at the exhibition booths. This is a figure that cannot be topped, and at same time is the highest level of satisfaction ever achieved at all NrnbergMesse events. The overall exhibitor satisfaction at the

People to seeing each other again.

know each other

and

look forward

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

last BRAU Beviale was 92 percent. We see this as a clear confirmation of the exhibition philosophy. But this does not prevent us from setting ourselves a target of nearly 100 percent in this area. Do you see a connection between high exhibitor and visitor satisfaction and specific event planning by NrnbergMesse during BRAU Beviale? What accompanying events are you planning in the exhibition company in 2006? Exhibitor information relating to innovations is one and, in our opinion, a particularly important side of the coin. The other side, of course, is accompanying events, which must be exactly aligned with the industry requirements. In the Logistics Solutions Center, a special exhibition, exhibitors will be presenting innovative products and services for optimizing the logistics 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, of course, RFID. The award of the European Beer Star on the second day of the exhibition is thematically well-suited to BRAU Beviale. The private breweries of Bavaria, the ideal supporting organization for the exhibition, have created this beer prize together with their European umbrella organization, the Association of Small and Independent Breweries. The objective was and is to advertise the wide variety of European beers. This year, the intention is to exceed the participation record of 400 beers from 23 nations. Since we have intentionally limited BRAU Beviale to three days in the interest of exhibitors and visitors, we do not promote any other events

during the period of the exhibition. This way, we do not distract the visitors from the actual objective of the exhibition, the making and development of contacts, any more than they would like. What we visualize for the future, however, is an event day in advance of the exhibition. We will first carefully assess the interest of exhibitors and visitors in this idea fully in accordance with our philosophy. BRAU Beviale has slowly but surely developed from a national to a European exhibition and has likewise slowly but surely expanded the target group of visitors from the brewing industry include 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 quotation from the man in the street, which says: A cobbler should stick to his last. The deliberate self-imposed restriction with regard to the target group is a very important factor for us of every top-class trade fair that is tailored towards specialists. By just this means, we produce an unbelievably high contact density and efficiency for which BRAU Beviale is also famous. This means that the subject areas of beverages and liquid food will always remain our core areas. As far as exhibitors and visitors are concerned, we will continue to focus on the German and European market. However, by agreement with the exhibitors, we will also address their extended customer target groups and are therefore planning additional activities in the near East, for example. Our general principle is that, as NrnbergMesse, we orientate ourselves consistently toward the interests of the exhibitor. We are certainly not going our own way here.

dialog+opinion Getting together at BRAU Beviale

18*19

The intentionally self-imposed restriction with regard to the is a very for us of every top-class trade fair that is tailored towards specialists.

the target group

the definition of

important factor

What about the duration of the BRAU Beviale exhibition and the booth restrictions? Is NrnbergMesse acting in the interests of the exhibitors? The answer to this is clearly yes. The three-day duration of the exhibition is completely in line with the exhibitors expectations. The majority of exhibitors see a clear efficiency advantage simply because of the incredible concentration of the exhibition period. If this situation should change, then we are naturally prepared to respond. For in everything that we do on the part of the exhibition company, the focus is very clearly on our customers the exhibitors. We are doing the right thing only when we are satisfying our customers wishes. And, in my opinion, the BRAU Beviale exhibition and NrnbergMesse can only continue as successful brands with this approach. The same applies to the booth restrictions. This is also oriented towards the exhibitors requirements. Limited booths means limited expense. Cost limitation of this kind has been implemented with great benefit for three years in a row. This also enables medium-sized companies, with which BRAU Beviale has grown up, to participate in the exhibition. 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 NrnbergMesse brands. Do you consider specific brand policy to be an important factor? In the case of consumer brands, we talk intensively about brand formation. I think brand formation is also important for exhibitions. We respond accordingly with advertising campaigns, press work, specific visitor marketing, and a high level of attention with regard to our image.

Apropos drinktec: In this regard, do you see the successful addition of an international event to the European-oriented BRAU Beviale? In my opinion, drinktec and BRAU Beviale complement one another so well that they can basically be looked upon as an overall industry concept.

Anyone who has followed the interview this far will know why he or she should attend BRAU Beviale from November 15 to 17. What is the situation regarding hotel accommodations? Will those deciding to go on short notice still be able to find a room? Nuremberg has an allotment of about 25,000 hotel beds. With 37,000 visitors to BRAU Beviale and 1500 exhibiting companies, hotel accommodations in and around the city could be scarce. Of course, we provide a room service from BRAU Beviale and will attempt to find the right accommodations for visitors at all times. If this is not successful within Nuremberg itself, I can recommend the surrounding area of Franconia, which has also shown itself to be extremely welcoming to guests. Here, for instance, you will find comfortable and charming brewery inns, which are easily accessible for those arriving by car. And here too, the much-lauded family character of BRAU Beviale can be lived and experienced every day before and after visiting the exhibition just as in the city of Nuremberg.

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

In Serbia-Montenegro, the beverage market is growing at breathtaking rates. Fruvita has built a strong market position in nectars, fruit juices, and fruit juice beverages. The company is considered a pioneer in the use of leading ACF technologies Made by KHS.
Fruvita in Serbia relies successfully on ACF with dry sterilization

THE FRUIT KING

task+solution

20*21

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

by beginning production of fruit nectars and launching Fruvita in 2003. In the first year, he had sales of 700,000 euros, and invested the same amount in marketing and advertising for his new beverage brand Hello. Success, as Redzic knows, can only be achieved in the long term with quality. He was already living according to this principle, when he founded an advertising journal for the Serbian market, which is still highly regarded today. For this reason, Redzic also relies on quality and the latest filling technology in his new beverage operation. This is also why the innovative KHS ACF technology (Aseptic Cold Filling) with the dry sterilization process is implemented at Fruvita. This allows Fruvita to eliminate preservatives completely in its fruit juice beverages.

4.5 million euros. In the same year, Redzic expanded his product range of ten nectars by adding five other fruit juice beverages. Redzic thus became the first Serbian provider of fruit juice beverages on the domestic market. Last year, sales more than tripled, to 15.2 million euros. The goal for 2006: a 100% increase in sales.
REDZIC RULE 2: ENCOURAGE INNOVATION

THE TASK

Installation

of an ACF system in very limited amount of space, which fulfills the strictest of hygienic requirements.

REDZIC RULE 1: ENSURE CONSISTENT QUALITY

THE SOLUTION

A KHS ACF line

The success of the consistent quality strategy is obvious: Today, Fruvita, with a market share of 25%, is number two among Serbian producers of fruit beverages, and is considered a pioneer when it comes to technical equipment. In 2004 one year after it was founded the companys yearly sales were already

Since 2005, Fruvita is offering not just fruit juice beverages and nectars, but fruit juices as well. Their largest sellers, however, are still the fruit juice beverages, with a 70% share of sales. Incidentally, the most popular style is multivitamin. Fruit juice and nectar are packaged in drink cartons, while the fruit juice beverages are bottled in 0.5 and 1.5-liter PET bottles. In my opinion, this is exactly the right style of packaging for a new and correspondingly modern drink on the Serbian market, says Goran Redzic.
REDZIC RULE 3: UTILIZE TECHNOLOGICAL ADVANTAGES

Their investment in KHS ACF system technology makes Fruvita one of the pioneers of ACF, not just in Serbia but also around the world. Redzic really didnt want to play the

in an L-shaped layout, which uses clean room technology with mini-isolators.

THUMBNAIL PORTRAIT: FRUVITA

Goran Redzic is a textbook businessman: Where other people see nothing, he finds market gaps and builds businesses. Redzic noticed a few years ago that among other things there was not a particularly great variety of fruit beverages being offered in Serbian market. He decided to change that

* Specialist in fruit-containing drinks * Market share in Serbia 25 percent * Sales 2003: 0.7 million euros 2004: 4.5 million euros 2005: 15.2 million euros Use of cutting-edge ACF Technology *

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.

part of the vanguard, however: While making our decision, we looked only at the advantages this technical equipment had to offer us. KHS ACF technology will allow Fruvita to offer the consumer a natural product without preservatives, bottled under the strictest of microbiological safety measures. By using the dry sterilization process, we benefit in comparison with the ACF wet process from extensive cost advantages with regard to the sterilization method and from the systems low space requirement, continues the company boss. Fruvita asked for the L-shaped layout to allow optimum integration of the line into the existing building. No problem for KHS. The modular concept is particularly excellent in that a variety of installation options is available even when space is limited.
The basic data of the new system:
* Capacity: 15,000 0.5-liter or 13,000 1.5liter PET bottles per hour.

* The bottling process takes place in the so-called mini-isolator where class 100 clean room conditions prevail. It is comprised of three components, the sterilizer, the activator, and the filler-capper unit. * The isolator is extremely hygienic and exceptionally space-saving. This compact isolator equipment houses only the PET bottle guide elements in the sterilizer and activator, as well as the filling valve outlets in the filler carousel, and the capping heads

in the capper. The filling valves themselves as well as all moveable parts, drives, and controls are located outside the sterile clean room. Parts and assemblies, which carry or generate contaminants have no contact with the sterile zone. Sterilizer/activator area. An air conveyor brings the non-refillable PET bottles to the KHS ACF block. There, the bottles first enter the sterilizer/activator area over an infeed plate that is free of format parts.

VALIDATION: A 100 PERCENT JOB

Before startup, the system must demonstrate its reliability in the area of hygiene. And this is how it was done: * For validation, Fruvita filled 10,000 PET bottles. * They were then stored at 28C for three weeks in a closed room. (The validation is successful if no more than a single bottle spoils.) * At Fruvita, not a single bottle was contaminated: We didnt expect anything else from KHS ACF equipment, says Goran Redzic.

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

22*23

Hydrogen peroxide (H2O2) sterilizes the plastic bottles inside and out. The hydrogen peroxide is not only evenly distributed on the interior and exterior surfaces of the bottle when it evaporates, but also condenses on undercuts, edges, and angles. This is a deciding factor for Fruvita especially, because the modern PET bottles have numerous indentations and to some extent a rough surface. The idea is to give the buyer the feel of holding a fruit when picking up the bottle. After the hydrogen peroxide is vaporized, warm air is introduced to activate the actual sterilization process. During that process, H2O2 breaks down into its components oxygen and water, and dries without leaving a residue. At Fruvita, one activator is enough. For higher filling capacity, two activators are recommended. An important factor in the filling process is supplying sterile air. The compact isolator technology provides two HEPA (High Efficiency Particulate Air) filters in the ceiling. They filter the air and guide it, sterilized, into the mini-isolator, with a sterile air flow, which moves in the direction opposing the bottle flow. The system guides the H2O2 and sterile air out of the clean room and exhausts them after the sterilization 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 and outfeed areas ensures additional safety by using overpressure of less than one bar to reliably prevent the entry of ambient air. Filling process. After cleaning, the PET bottles move into the filler, in which Fruvita bottles only non-carbonated fruit juice beverages. A two-stage, open-jet filling valve fills the PET bottles without pressure. This valve is an all-rounder: It can fill either pulp-containing or thick non-carbonated beverages. A magnetic-inductive flow meter regulates the volumetric filling process. A special highlight: The line is controlled locally by a new KHS system that controls the filling block fully automatically and records all data in real-time at each filling valve, monitors the filling process, and regulates the production process. All parameters pertaining to the filler control are stored in so-called recipes for different products,

bottle sizes and shapes, and filling capacities. When the system switches recipes, all the data needed is loaded into the filler control unit. The result: The cleaning and filling process starts reliably guaranteed process reliability at the press of a button. The system directs the information gathered to the KHS plant information system AIS for the monitoring of all critical system points in the aseptic area. Safety and hygiene. Maximum microbiological safety has the top priority in the KHS ACF block. The system provides reliable information on sanitizing and disinfection cycles. Main sanitizing of the system is performed every 48 to 72 hours, which also includes the complete CIP and SIP cycles as well as the sterilization of the mini-isolators. In addition, the surfaces are automatically disinfected every four hours. If

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

Left Fruvitas 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.

work is necessary inside the clean room area, a special sterile air control is able to separate individual mini-isolator areas and sterilize them quickly. Everything, but absolutely everything, is really well controlled here. More safety would really not be possible, summarizes Goran Redzic enthusiastically. Behind the filling system, there is an ACF-compliant Innofill SV-ACF capper. As with bottle sterilizing, hydrogen peroxide is also used to sterilize the caps. This process is performed in the separate cap sterilization unit. Of course, even in this standalone machine, all the significant process parameters are monitored and logged in AIS.
REDZIC RULE 4: QUALIFY STAFF

REDZIC RULE 5: EXPAND SUCCESS ACCORDING TO PLAN

The success and quality of Fruvita beverages are internationally discussed: Even beyond Serbian borders, there is a significant interest in high-quality Fruvita products in the meantime. The first exports went to Bosnia and Macedonia. Meanwhile, export accounts for ten percent of total sales of fruit juice

beverages. The demand here is therefore greater than the supply. Redzic: We are using KHS ACF equipment in four-shift operation. That is still not enough for our customers.
Manfred Keller, Sales Manager South-East Europe, KHS AG, Bad Kreuznach Andreas Flora-Asendorf, Project Manager, KHS AG, ACF Filling Technology Competence Center, Hamburg

Despite all the safety systems, however, any installation is only as good as its operating personnel. Thats why KHS provides an extensive training program for Fruvita employees on topics relevant to hygiene. Praise from Redzic: The employees involved with the new ACF block are now well acquainted with hygiene measures and, at the same time, highly motivated. Specific KHS training courses have made a decisive contribution to this. We are also pleased with the comprehensive advice provided by KHS. For example, KHS has supported us in every aspect of setting up our ultra-modern laboratory.

INFOBOX

WEBSITE www.fruvita.co.yu

CONTACTS

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

Tel: +49 (671) 852-2655 E-mail: manfred.keller@khs.com

Andreas Flora-Asendorf, Project Manager, KHS AG, ACF Filling Technology

Competence Center, Hamburg

Tel: +49 (40) 63703-36139 E-mail: andreas.flora-asendorf@khs.com

task+solution

24*25

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: Its easy walking on the aerial photograph of Krems and surrounding winegrowing towns.

Winzer Krems: Austrias largest viticultural cooperative has a tradition of innovation

The Keg Wine Pioneers

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 love of 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.

The viticulture in the vicinity of the city of Krems can be traced back at least to the third century A.D. The heart of regional winegrowing beats in the valley of the Danube, at the entrance to the Wachau, the gateway to one of the most beautiful river valleys of Europe and Austrias finest vineyards. Thanks to the interplay of microclimates supported by river currents and the valleys protected from the north, along with perfect soil, it is possible to produce a variety of different types and qualities under ideal conditions. So its no wonder that Winzer Krems, now the largest viticultural cooperative in the country, has its home here. Our standard is solely quality. We therefore traditionally follow innovative methods in order to provide our customers with the authentic natural product, Krems wine, flawless in all respects, stresses Franz Arndorfer, Chief Cellar Master of the coop-

erative. Literally all facets. Because Winzer Krems not only utilize the strictest of standards in growing and in winery operations, they also market their wine off the beaten path, thus representing a role model for the entire industry.
EXPERIENCE WINE

In August of 2005, Winzer Krems started the unique visitor experience program wine sense, which celebrates wine at eight stations as an experience for the senses: At the first station, the vineyard, there are 18 varieties of grape planted around the traditional Hiata the hut of the vineyard custodian. The second station offers a walkon aerial photo of Krems and the surrounding winegrowing towns. The third stop is the old domed cellar containing a selection of rare wines. There are wines here, for instance, from the 1948 vintage, guarded

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 light and music production allows them to reveal old secrets and new know-how about these stored treasures. From the fourth station, the stylish barrique cellar, the visitor has an impressive view of the cooking and storage tanks, illuminated in rich green. In the tasting room, the guest can then also taste the wine impressions already seen, heard, and felt in the stylish atmosphere of the Winzer Krems brand. The conclusion is then in the eighth station, the wine shop, where not only wines but also other specialties, such as wine chocolates, are available. The concept is well accepted. In mid-2006 we greeted the 20,000th visitor to our world of wine experience. Our vineyard sales grew by 33% compared to the previous year, Franz Ehrenleitner, Managing Director of Winzer Krems, says enthusiastically. The wine cooperative has mediumterm plans for about 40,000 visitors per year from at home and abroad.

WINZER KREMS, KEG PIONEER

Advantage I: Overall stability

A total of nearly 10 million liters of Winzer Krems quality wines are produced by the cooperative each year. A particular feature sets the cooperative apart: Although the wines are delivered to end consumers and restaurants in the industry-standard bottle sizes and shapes commonly used by other wineries as well, Winzer Krems also delivers wine to restaurants in kegs. Truly groundbreaking. The company started filling wine in kegs as far back as the mid-1970s. Today, kegs represent 10 percent of their overall sales while the keg share in the restaurant sales sector is 40 percent.
KEG TECHNOLOGY, COMPELLING DUE TO ADDED VALUE

The kegs are hermetically sealed, opaque, taste-neutral, resistant to corrosion and impact, and allow nearly unlimited storage times without affecting the quality of the wine.
Advantage II: Long service life

Since deposits are mandatory for kegs, they are environmentally friendly and have an extremely long service life 30 years of use is not uncommon. Winzer Krems racks one keg an average of four to five times a year. In all, the viticultural cooperative owns 10,000 kegs, 8,000 of which are 25-liter kegs, and 2,000 are 50-liter kegs.
Advantage III: Little handling effort

Not without reason, because keg technology offers both the cooperative and their customers a series of advantages. We see clear advantages in kegs, confirms Franz Arndorfer.

SPOTLIGHT: KEG FILLING AT WINZER KREMS

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

Restaurateurs like wine in kegs for their small amount of handling. After the onetime fitting of the tap, they can tap the keg without additional work or maintenance steps until it is empty. This eliminates timeconsuming opening of bottles, along with the negative affects of bottle corks on the taste. And, wine from the keg is always at the right dispensing temperature thanks to the control system in the dispenser. But Cellar Master Arndorfer knows that many restaurateurs are skeptical of wine in kegs. Thats why restaurant businesses that rely on wine in kegs must be trained individually. In Austria just as in

task+solution Winzer Krems: Austrias largest viticultural cooperative has a tradition of innovation

26*27

2
* * * * * *

THUMBNAIL PORTRAIT: WINZER KREMS

Cooperative founded in 1938

Today Austrias 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 Grner Veltliner, Riesling, Chardonnay, Mller-Thurgau, Pinot Blanc, and Muscatel, and 30% in red wine grape varieties, including Blauer Zweigelt, St. Laurent, Blauer Burgunder, and Blauer Portugieser.

the export market of Southern Germany. The best arguments are the more than 30 members of the external sales staff on site and Kremser quality: If the keg were not such a high-quality container, we would certainly not trust it with our outstanding quality wines, says Managing Director Ehrenleitner, the traditional supplier of the Viennese Opera Ball.
KHS SATISFIES DEMANDING REQUIREMENTS

Perfect keg cleaning and gentle filling guarantee the best wine quality in the keg. Cellar Master Arndorfer: We have relied specifically on KHS keg technology for many years. Its precisely wines like the fruity Grner Veltliner for which it is important to retain the natural effervescence. Only gentle filling reduces the pickup of gas and oxygen into the wine to an absolute minimum. After delivery, the empty kegs pass through the Innokeg AK 1 external washer.

A spray nozzle system cleans the outside surfaces with caustic and warm water. The cleaning times can be regulated individually depending on the degree of contamination of the kegs. Then the fresh water spray removes any remaining cleaning agents. An integrated control system monitors the external cleaning process. The clean kegs then move on to the single-lane Innokeg Till TRANSOMAT 3/1 washing and racking machine. The KHS keg line installed at Winzer Krems works on a one-shift schedule, filling up to 60 kegs per hour. The Innokeg Till TRANSOMAT 3/1 is not only able to fill red and white wines; it is also capable of filling of champagne in kegs ranging from 7 to the 58 liters in size. Cellar Master Franz Arndorfer: We focus consistently on the market. If, in the future, the end consumer wants wine in kegs in smaller container sizes, then we are just as open to this as we are to an increased demand

by the restaurant trade for sparkling wine in kegs. It remains to be noted that with keg technology, Winzer Krems is ready for future pioneering in this sector.
Michael Schlegel, Central Product Support, KHS AG, Bad Kreuznach Volker Geng, Manager KHS Austria, Wiener Neudorf

INFOBOX

WEBSITE www.winzerkrems.at CONTACT

Michael Schlegel, Central Product Support, KHS AG, Bad Kreuznach Tel: +49 (671) 852-2764 E-mail: michael.schlegel@khs.com Volker Geng, Manager KHS Austria, Wiener Neudorf +43 (22 36) 62510-229 Tel: E-mail: volker.geng@khs.com

Jazak Mineral Water, Serbia: The slightly different success story

Perfect Connection
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.

THE TASK

Sate-of-the-art PET system technology

2. Success factor: Quality. Jazak mineral water is known for its

with options for expansion and service from one source.

excellent quality, due, among other things, to its good calcium to magnesium ratio (76.1 mg/l calcium, 42.5 mg/l magnesium) and its low sodium content of 8.3 mg/l.
3. Success factor: Marketing network. The group Petroleum

THE SOLUTION

Two complete KHS PET bottling lines modular in design, able to fill 0.5 up to large-size 5 liter PET bottles.

Industry Serbia works closely with filling stations to market fuel. Hence, since 2005, about 1000 filling stations sell not only the groups fuel, but also its mineral water.
4. Success factor: Employees. CEO Stojanovic sees the large number of employees in the overall group as another marketing volume reservoir. They not only can drink their own water, but also act as multipliers to report on the advantages of the water.
GREAT MARKET POTENTIAL

Oil and water as we know from basic chemistry dont mix. At Jazak Mineral Springs in Serbia, exactly the opposite is the case: here, oil and water attract. Thats because the mineral springs, as a subsidiary of Nis-Naftagas, belongs to Petroleum Industry Serbia. Although Nis-Naftagas, founded in 1949, primarily explores and develops oil and gas fields, it is also specialized in water resources. Slavoljub Stojanovic, the CEO of Jazak, lists four significant success factors, which make this combination of oil and water so 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 exploratory company like Nis-Naftagas? Before Jazak Mineral Springs opened, Nis-Naftagas started several selected drillings. The result: Nis-Naftagas discovered a source with outstanding mineral water quality in the town of Jazak in the north of Serbia, in the Serbian province of Vojvodina.

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 Montenegro is currently about 50 liters per year. If the development of water consumption over the past decade is examined, it becomes clear that the water market still has potential. For instance, in 1996, consumption of bottled water was only about 16 liters per capita. In 2003, that figure was already 44 liters. According to Stojanovic, a convergence with western European consumption levels is entirely conceivable. That would equal a per capita consumption of nearly 100 liters.
SALES HIT: 5-LITER PET BOTTLE

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

task+solution

28*29

Slavoljub Stojanovic, Managing Director of Jazak mineral springs: KHS equipment satisfies our high quality expectations to the maximum possible extent.

the 5-liter PET bottle is astoundingly their top seller. Especially as a family bottle, the 5-liter PET bottle is extremely popular, says CEO Stojanovic. About 55 percent of all sales are realized by this jumbo size, followed by the 1.5-liter bottle with 30 percent.
STRENGTH, SIZE, AND QUALITY

Strength, size, and quality those are also the criteria determined by Nis-Naftagas for the selection of the bottling and packaging technology for the mineral water. Slavoljub Stojanovic says: With KHS, we are dealing with an equal partner, who has worldwide knowhow and the best references in its sector. The company has invested in two KHS turnkey lines. KHS supplied all the technical equipment. While one line processes the 1.5-liter and 0.5-liter PET bottles at an output of 9,000 1.5-liter PET bottles /h, the second line is designed to process 5-liter PET bottles 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 mineral water (completely glass-enclosed, maximum microbiological safety). Computer-controlled normal pressure filling system Innofill NRF (bottom-up, gentle filling). Simple, fast cleaning (all surfaces from the ring bowl to the filling valve are smoothed, with membrane technology in the valve area).

2
* * * *

THUMBNAIL PORTRAIT: JAZAK

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)

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

* *

Rinsing process using mechanically controlled, single-channel Innoclean FR-EM rinser. Single-chamber pressure filling system Innofill DMG (non-carbonated 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 (robotcontrolled, modular dry area concept).

INFOBOX

THE RESULT: PERFECT QUALITY

WEBSITE www.nis-naftagas.co.yu

CONTACT Manfred Keller,

Sales Manager, South-East Europe, KHS AG, Bad Kreuznach Tel: +49 (671) 852-2655 E-mail: manfred.keller@khs.com Nenad Delovski, Manager of KHS office in Belgrade, KHS AG Tel: +3 (81) 113119-725 E-mail: nenad.delovski@khs.com

Both lines satisfy our high quality expectations to the maximum possible extent, summarizes Stojanovic. The new KHS line technology gives Jazak what it needs to conquer the domestic mineral water market. There are currently about 40 different mineral water brands on the market in Serbia and Montenegro. Jazak not only wants to remain one of them, but also to become the most successful brand of mineral water. Stojanovic: With the help of our strong parent company, Nis-Naftagas, we can succeed in this more quickly than 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

The success story of the Stiegl Brewery, Salzburg, goes merrily on

Record in
The more than 500 years young Salzburg Stiegl Brewery is repeatedly in the news with publicity-oriented innovations. That such a strategy should pay off is shown by the record sales in the month of July: 95,000 hectoliters the highest sales figures in half a millennium. And all this in Mozart year, to which the Stiegl Brewery has dedicated a number of its inspiring ideas.

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.

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 practiced by the Stiegl Brewery with headquarters in Salzburg. For over 500 years a quality philosophy has prevailed here, which began in the middle of the old town of Salzburg in 1492 in the former Prewhaus auff der Gestetten and bey dem Stieglein (the little staircase). As the best-known son of the town on the Salzach, Wolfgang Amadeus Mozart, recorded in his diary, the Stiegl Brewery was already almost 300 years old when he visited it together with his sister Nannerl in 1780. Whether the art of brewing provided inspiration for Mozart for one or other of his musical compositions can neither be confirmed nor denied. However, it is certain that the maestro is a welcome inspiration for the Stiegl Brewery not only in the Mozart year 2006. At any rate, Master Brewer Ernst Schreiner views this pragmatically: The Stiegl Brewery has a quite definite location 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 bottle edition. * A year earlier, the brewery encouraged students at the University of Applied Art in Vienna to develop Mozart labels. With 327 designs, the jury was able to draw on plentiful resources. * The Mozart 2006 edition has made an appearance at all of this years Mozart events in Salzburg.

task+solution

30*31

Mozart Year
* The www.mozart.at website initiated by the brewery provides

news, information, and events on all aspects of Mozart. * At www.mozartland.com, Mozartland, a 100-percent subsidiary of the Stiegl Brewery, mainly provides opportunities for shopping. The company also demonstrates creativity with the recently introduced 0.33-liter non-refillable glass bottle. Young adults in particular are enthusiastic about the container with its retro-look styling and a label in the Stiegl style of the 1960s. Marketing Manager Markus Oberhamberger explains: As a private Austrian brewery, we have confidence in ourselves and take a different path from the international brewery groups. We are once again living up to this claim with our new 0.33-liter bottle. And Ernst Schreiner adds: Modern packaging and retro-design harmonize here in accordance with the motto: Opposites attract.
BREWING AND CULINARY ART COME TOGETHER

a continuous increase in sales. Schreiner predicts: We are also expecting 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 of beer varieties including Mrzen, Pils, Zwickl, wheat beer, special beer, bock beer, light beer, Paracelsus (bio-beer) and shandy, it continues to be the Mrzen beer known as Stiegl-Goldbru that particularly takes the fancy of the Austrians. The company realizes more than 90 percent of total sales with this style of beer. Among other things, Schreiner believes that the reasons for this lie in the past. In Austria, softer beers such as the Mrzen beer have always been particularly popular. This goes back to the time of the monarchy.

In this sense, Stiegl is cooperating with domestic culinary art at its finest. For, according to the brewery, Stiegl beer specialties are not only suitable for pure enjoyment, but equally for cooking as well. A brochure with the title Koch- & Braukunst auf hchster Stufe (The Art of Cooking and Brewing at its Finest) has now been published in cooperation with master chef Simon Taxacher. Especially designed for the restaurant trade, this standard work provides delicious beer recipes for the reader to make. Demand is enormous. Four reprints have therefore already been commissioned. The publication includes fine beer recipes for asparagus, for broiling and for various uses of mushrooms, all presented by Austrian master chefs. It goes without saying that there is a recommendation by the Master Brewer for the most appropriate beer for every meal.
LARGEST PRIVATE BREWERY IN AUSTRIA

2
* * * * *

THUMBNAIL PORTRAIT: STIEGL BREWERY

Brewer of beer for more than 500 years Main brand: Stiegl-Goldbru Market share in Austria: 11 percent Brand awareness: 91 percent Output 2005: more than 900,000 hectoliters

MOZART PLUS WORLD CUP EQUALS MAXIMUM PERFORMANCE

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

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

The Brewery mainly sees its market in Austria and brews the beer of the Austrians. The export share is just one percent. Export countries are Germany, Italy, the U.S.A., and Canada. The Master Brewer: We still see a great deal of potential on the domestic market. Added to this is the fact that, as a company that practices the art of brewing at its finest, we want to be local to our customers in order to be able to provide a correspondingly top level of service quality at all times. The in-house Quality Service Department for the restaurant trade is also geared towards this. With this department, the Stiegl Brewery traditionally provides a unique service. The aim of the quality team, which is active throughout Austria, is to raise and secure the level of beer culture in restaurants.
Output up to 40,000 bottles per hour. Today, the line is operAND A TOP-LEVEL TECHNICAL SOLUTION

Quality is also the most important aspect of bottling and packaging the quality beers. Our quality strategy, says Schreiner, only allows the best technical solutions to be used. We will not be satisfied with less. It was obvious to Schreiner that it would once again have to be KHS for the most recent investment. On the one hand, the latest technical solutions, which could be visited in advance at reference installations by the Stiegl Brewery team, were very convincing. On the other, KHS equipment has impressed over and over again in the companys own plant for many years. The company has just recently invested in the latest KHS bottle washing technology. The new single-end bottle washer processes 72,000 bottles per hour and offers considerable savings on water, energy, and cleaning media while maintaining excellent cleaning action. Investment is currently being made in the replacement of a wide range of modules: Rinser-filler-capper block, flash pasteurizer, inspection equipment, and crater on a former refillable line, which has now advanced to become a combined refillable/non-refillable bottle line by installing an additional rinser. On the other hand, triedand-tested KHS equipment, which has unhesitatingly provided outstanding service for more than two decades, has been discarded.

ated with an output of 28,000 0.33-liter non-refillable and 24,000 0.33-liter or 0.5-liter refillable bottles per hour. With the new machine components, an output of up to 40,000 0.33-liter bottles per hour or 35,000 0.5-liter bottles per hour would be entirely feasible. The limiting factor here is the existing machines, namely the labeler and the bottle washing machine. The successful harmony between old and new became clear during the acceptance of the line: The efficiency was 98 percent. A mechanically controlled Innoclean FR-ZM double-channel rinser handles the task of rinsing the non-refillable glass bottles. It is designed for rinsing with two different types of media. After disinfection with chlorine dioxide, the bottles are rinsed with sterile water. Low-oxygen-pickup filling saves CO2. The computer-controlled Innofill DRS-ZMS pneumatic pressurized filling system is equipped with 108 filling stations and guarantees the high quality of the Stiegl Brewerys beer due to the extremely low oxygen filling process. It allows new sizes and shapes of bottle to be processed at any time and works with filling level probes. The CO2 consumption is an excellent 230 grams per hectoliter of beer; the O2 pickup is a very good 0.02 mg/l. Other benefits include short changeover times, high machine availability through central filling level adjustment, speed-

task+solution The success story of the Stiegl Brewery, Salzburg, goes merrily on

32*33

Left Innofill DRS-ZMS: Safeguards the high quality of the Stiegl Brewerys 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 Brewerys 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 automatically; new components are then picked up and installed one after the other in the packing machine also fully automatically. The only manual intervention necessary is to couple the connecting hoses for the power and air supplies.
HIGH PRAISE FROM THE MASTER BREWER

and standstill-independent processing sequence, adjustment to suit the current line output, freedom from external mechanical control devices, and aseptic sealing systems in all product and gas passages. Master Brewer Schreiner praises: It doesnt 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 blocked with a crown cork capper for non-refillable and refillable bottles, and a ring-pull capper especially for 0.33-liter refillable bottles. An interesting item: An interesting feature is the twist crown cork cap fitted to the bottles by the crowner. It is especially liked by the young target group on the 0.33-liter non-refillable bottles. Exact filling level and cap checking. Immediately after the filling and capping process, the bottles pass to the Innocheck PROMECON 2000 filling level and cap monitor where the filling level is checked using x-ray technology, the presence of the cap is checked using a sensor, and the seating of the cap is checked by means of a laser light barrier. Fully automatic format changing system. Good bottles go to the Innopack PPZ crater, a latest generation twin-axis machine with outstanding accessibility, simple controls, and a fully automatic KHS format change system. All format part changing for complete

Ernst Schreiner emphasizes once more: We are extremely satisfied with KHS solutions. KHS has taken our high quality requirements fully into account. This way, the success story of the Stiegl Brewery continues in the same vein. Incidentally, in 2007, for the first time, the entire population of Austria (instead of a jury) will decide which six labels are to appear on art-of-brewing edition bottles. Stiegl is certainly the brewery from and for Austria.
Gnter Unkrig, Director, Central European Sales Region, KHS AG, Dortmund Volker Geng, Manager KHS Austria, Wiener Neudorf

INFOBOX

WEBSITE www.stieglbrauerei.at CONTACT

Gnter Unkrig, Director, Central European Sales Region, KHS AG, Dortmund Tel: +49 (231) 569-1602 E-mail: guenter.unkrig@khs.com Volker Geng, Manager KHS Austria, Wiener Neudorf Tel: +43 (2236) 62510-229 E-mail: volker.geng@khs.com

Voda Voda: Unique overall concept

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

WATER TO THE

task+solution

34*35

POWER OF
1
THE TASK

Installation of a complete glass bottling line

His water has recently been awarded the renowned American NSF certificate by the independent National Hygiene Foundation. The upshot in any event is that the water has the potential to refresh connoisseurs around the globe. But how does one make it clear to the customer that this water 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 company quite simply Voda Voda. And, translated, this means Water Water.
UNIQUE: THE BOTTLE

for square bottles and adhesive-pressure labeling.

Another important element in the integrated marketing concept is the bottle itself. It is not round, but square; it bears the Voda Voda inscription embossed in relief, and takes one by surprise with a clear no-label-look adhesive-pressure label.
UNIQUE: THE MARKET POSITION

THE SOLUTION

A complete KHS system with Voda Voda is already the market leader in the still mineral water sector in Serbia and Montenegro. Sales have climbed from 10 million liters two years ago to 30 million liters last year, and this year Voda Voda is aiming for the 50-million-liter mark. According to Djordjevic, things are expected to continue with similarly large sales increases. Later this year, the company intends to launch a sparkling mineral water version with the name Voda Voda 2. Since the beginning of the year, the non-carbonated water has not only been bottled in PET but also in glass bottles. This is expected to greatly improve sales in the restaurant trade in particular. Glass bottles are currently only available on the market in the 0.33-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 in total account for 75 percent of sales. The proportion of glass and PET bottles are later expected to balance out.
UNIQUE: THE PRODUCTION FACILITY

gentle, single-lane bottle conveying and an Innoket Roland adhesive-pressure labeling machine. Some products present marketing experts with a great challenge. For, at first sight, these products cannot be distinguished from one another. Surely, the most demanding product in this regard is water. It is odorless and colorless and even the carbon dioxide content is impossible to detect before the water sparkles in the glass. The matter is not made any easier by the fact that shares in the water market are strongly contested and new suppliers find it doubly difficult to establish themselves. But exactly this challenge has stimulated Vojin Djordjevic, President of the SI&SI Group in Serbia 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 marketing strategy. The Vrujci source there has been known since the end of the 19th century, and the people of Banja Vrujci attribute healing and beneficial effects to the spring water. Entrepreneur Djordjevic sees this rather more pragmatically: Numerous analyses by national and international institutions have confirmed the traditions and show that the source produces water of the best possible quality.

Also sophisticated and spectacular are the Voda Voda bottling shops, for the factory bays are basically more design objects than production facilities the ideal location for bottling the extraordinary spring water. What is more, the water passes almost directly from the source to the bottle without any processing and without long transport routes through pipes. There is a height difference of

Voda Voda: Unique overall concept

exactly 273 meters that the precious liquid needs to negotiate from the source in the depths to the filler, which is almost directly above it.
UNIQUE: THE BOTTLING EQUIPMENT

THUMBNAIL PORTRAIT

The sophisticated bottle shape and the outstanding water quality also demand correspondingly high-quality technical solutions for filling and packaging. The finest KHS equipment is also part of the story. The best is just good enough, Djordjevic demands and continues, We have used KHS equipment within the SI&SI Group for several years. To the present day, we are highly satisfied with the technical solutions and service from KHS. We have a partnership with KHS just as it should be.
The best features of the new line in brief:
* *

* Serbias 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 largest

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 with plastic panels. Innoket Roland 16 H adhesive-pressure labeler with a specially designed feedscrew for square bottles.

wine cellars in Serbia) / Gorki List (most important Serbian herbal liqueur) * Joint Venture with Sinalco International (Sinalco Serbia produces immediately next to Voda Voda and values the outstanding water quality of Voda Voda for its own beverages).

* *
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.

Completely enclosed rinser-filler-capper block with the Innoclean FR EM rinser blocked with the Innofill DMG filler and 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 with KHS has continued in the most positive sense with the new plant equipment. We are highly satisfied. Innovative KHS equipment is an important basis for a very special and continuing Voda Voda success 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

INFOBOX

WEBSIDE www.vodavoda.com.sg CONTACT

Manfred Keller, Sales Manager South-East Europe,

KHS AG, Bad Kreuznach Tel: +49 (671) 852-2655 E-mail: manfred.keller@khs.com Nenad Delovski, Manager of the KHS Branch Office Belgrade, KHS AG Tel: +3 (81) 113119-725 E-mail: nenad.delovski@khs.com

task+solution

36*37

Saudi Arabias Pepsi bottler with high-performance canning lines

Sipco Sets an Example

1
THE TASK

An optimum Pepsi-Cola filling system for Saudi Arabia that considers the conditions of the country, sets standards, leaves room for individuality.

The high-performance canning line delivered by KHS for Saudi Industrial Projects Co. (Sipco for short), with an output of up to 90,000 cans per hour, is a textbook example for the Saudi soft drink industry. In the past four years alone, this licensing partner of Pepsi-Cola has ordered five of these lines. Sipco: the model case.
In Saudi Arabia, too, KHS has a proud tradition. Many KHS filling lines from the 80s, particularly those for soft drinks, are still running here today to the full satisfaction of their operators. And, the market for these beverages is firmly in Pepsis hand. Pepsi-Cola, Seven Up, Mirinda, Shani, and Mountain Dew have a market share of more than 90 percent. Particularly the younger generation consumes soft drinks, primarily in cans. They are attractive due to convenience and protection of the product at high temperatures. In the past four years, KHS has shipped six high-performance canning lines to Saudi Arabia. Five of those were ordered by franchising partners of Pepsi-Cola International. One system went to the Abuljadayel bottling plant in Jiddah, a major producer of fruit juice and energy drinks. Pepsi-Cola International has four licensing partnerships in Saudi Arabia: * In Riyadh, the largest city in Saudi Arabia with 4.1 million inhabitants, Al
Jomaih Bottling & Can Making Co.

THE SOLUTION

Ultra-modern

can filling technology that offers high line efficiency, establishes national standards, and is still highly flexible.

produces for the central and northern regions of the country.

*

Saudi Industrial Projects Co. (Sipco)

is based in Jiddah on coast of the Red

Sea (2.8 million inhabitants, second largest city, western region).

*

TOP STANDARD FOR THE ENTIRE COUNTRY

Abdel Hadi Abdallah Al Qahtani & Sons in Khamis Mashayt (southwest

region).
*

Ahmed Hamad Algosaibi & Bros. National Bottling Co. has its head-

quarters in Al Khobar on the Gulf of Arabia near the large city of Dammam (eastern region). From 2003 on, the KHS success story has continued with the delivery of a high-performance canning line to Saudi Industrial Projects Co. (Sipco) in Jiddah. Here, the partners are setting an example with stateof-the-art technology, in the truest sense of the word. The system processes 90,000 cans per hour and runs in three shifts. The line efficiency remains in the high nineties even today.

A truly impressive performance. Praise from A. Amer S. Morshed, General Manager Sipco: We expected KHS quality with the best results, but our expectations were even exceeded. For us, it was therefore natural to use only KHS turnkey systems for additional filling systems. Sipco ordered a second KHS high-performance canning line in 2004. Oriented towards this Sipco Model that has become a standard, a canning line went to Al Jomaih Bottling & Can Making Co. in the same year. And recently, Abdel Hadi Abdallah Al Qahtani & Sons and Ahmed Hamad Algosaibi & Bros. National Bottling Co. also both ordered this type of model system. Of course, always customized to the wishes of the customer. Even at Sipco, the

two newest plants are not identical to the last detail. They process the 0.355-liter can, which is particularly popular in Saudi Arabia for Pepsi brand beverages. The lines run in parallel with one another that saves space.
THE SIPCO MODEL IN 10 STEPS

Empty cans enter the lines by the pallet. An operator removes the securing straps. An Innopal ASH can depalletizer is in operation for each of the two lines.

The system sorts faulty cans out using a vacuum bridge. Good cans are conveyed directly to the appropriate rinser (mounted diagonally), which moves the cans down to the height of the filler during the cold water rinse.

task+solution Saudi Arabias Pepsi bottler with high-performance canning lines

38*39

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.

ing system works with a Brix measurement and control system. After the filling and seaming process, the cans are turned upside down and conveyed to the Innopas can heater where the cans, filled at a product temperature of 15 degrees Celsius, are heated to about 30 degrees. Indispensable in an environment with peak temperatures of up to 50 degrees and high humidity in order to avoid condensation on the cans.

Standing on their heads, the cans are then sent to the coding unit. Any liquid clinging to the outside of the cans is blown off before an inkjet printer applies a special can code.

The heart of the line, a computer-controlled Innofill DVD volumetric filler system, stands for maximum filling level accuracy using electromagnetic induction flowmetering. Deviations in can capacities supplied by various manufactures are no longer a matter of concern. This saves a considerable amount of product. Different can variants can also be processed at the press of a button. Advantages: Time savings and increased machine availability. Format part changing is necessary only if a different can diameter is to be processed. Blocked: The seamer.

After uprighting the cans in the twister, they travel towards the packing and palletizing system, which has different layouts in the two lines (1 shrink packer / 2 tray shrink packers / 2 palletizers vs. 1 Innopack Kisters TSP 100 V tray shrink packer and 1 high-flexibility palletizer).

General Manager Al Jomaih Bottling & Can Making Co., is also enthusiastic about KHS technology. This franchising partner of Pepsi-Cola International took delivery of a canning line at nearly the same time as Sipco. Elie J. Fayad: The KHS concept for Sipco had us convinced. We just wanted a few operation-specific adaptations on our end. More can sizes for instance from 150- and 250-milliliter slim cans up to 330- and 355milliliter standard cans. Or the transfer of the packaged cans to the palletizer: It runs more than 250 meters over a bridge to the other side of the street. And the KHS success story in Saudi Arabia hasnt ended yet: Aduljadayel took delivery of a high-performance canning line based on the Sipco Model, of course and also ordered a non-refillable glass line designed for an output of 72,000 bottles per hour. KHS quality is compelling.
Erhard Magin, Director for Africa, Middle East, and Southern Europe Sales Region, KHS AG, Bad Kreuznach Manfred Seifert, Middle East Sales, KHS AG, Bad Kreuznach

The new KHS Innopal PBHS high-performance palletizing system is a single-station robot with pallet elevator above and a two-piece pusher plate with a maximum capacity of up to 700 layers per hour.

INFOBOX

WEBSIDE www.pepsico.com CONTACT

The newer line is already designed 10 according to the modular dry area concept with PC-based robot controls. Only a single intelligence is used here.
PARTNERS HIGHLY SATISFIED

Erhard Magin, Director for Africa, Middle East,

The precision fill level and sealing control system is next. Also Integrated: filling valve management.

The Innopro Paramix CMX doubledeaerating, mixing, and carbonat-

Ron Beatson, Sipcos Plant Manager, summarizes: We are and will remain KHS fans. Its no coincidence that a large part of Sipcos plant engineering is from KHS. Elie J. Fayad,

and Southern Europe Sales Region, KHS AG, Bad Kreuznach Tel: +49 (671) 852-2675 E-mail: erhard.magin@khs.com Manfred Seifert, Middle East Sales, KHS AG, Bad Kreuznach Tel: +49 (5704) 16050 E-mail: manfred.seifert@khs.com

6
1
THE TASK

Pepsi-Cola, Iraq: Licensing partners placing trust in KHS equipment

Lines in 2 Years
In Iraq, water is the most popular drink, followed closely by tea and soft drinks. In the latter category, the clear favorite is Pepsi-Cola (the bubbly beverage has been in the country since 1950). The most important franchising partner of Pepsi-Cola International in Iraq is Baghdad Soft Drinks, with headquarters in the capital city of Baghdad. Operations started in 1984 with the production of Pepsi-Cola and the soft drinks 7-Up and Mirinda, both members of the Pepsi brand family. Already in use at that time: eight refillable glass bottle lines, along with one canning line, all from KHS. But in 1991, the United Nations embargo cut the company off from its supply of concentrate. The UN sanctions were not lifted until 2003 the beginning of a new Pepsi era. In the meantime, the distribution region of Baghdad Soft Drinks includes the city of Baghdad, with five million inhabitants, along with its northern vicinity. That means the company reaches about 40% of the 27 million inhabitants of the country.

The four licensees of Pepsi-Cola International in Iraq fill their beverages nearly exclusively using systems from KHS. Within the past two years, they have invested in six lines. The last were one PET bottling line and one canning line.

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.

task+solution

40*41

Today, Pepsi-Cola International has another three licensing partnerships in Iraq: in Al Kufah (100 kilometers from Baghdad), in Basra (with a population of two million people, the second largest city in the nation, and the center of the Shiite south), and soon in Arbil (the capital of the autonomous region Kurdistan, with about one million inhabitants.)
QUALITY OVER DECADES

When Baghdad Soft Drinks reemerged as a franchising partner of Pepsi-Cola International in 2004, a new KHS era started there as well. The most important reason: great satisfaction with KHS system technology from the year 1984, which served faithfully for decades and to some extent is still working today. But markets change. Refillable glass bottles continue to be the style of packaging of choice in Iraq although it is slowly starting to lose ground to cans and PET bottles. And KHS technology has always been there. Since 2004, when KHS experts refurbished the 20-yearold 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 to those used in the solutions delivered in 2004. Dr. Hamid Jassim Khamis Hamed, Managing Director at Baghdad Soft Drinks, explains: Excellent KHS system technology needs no improvement. The board of National Bottling Company in Al Kufah sees it the same way. Here, too as with the other Pepsi licensing partners KHS technology has been in operation for years. And the current new canning and packaging technology is once again from KHS.
PET TECHNOLOGY

Labeling of bottles before the filling process (Innoket RF 25). * The mechanically controlled pressure filling system Innofill DMG-VF is predestined for filling of soft drinks in PET bottles. Director Hamed: The robust, low-maintenance, and extremely user-friendly KHS filling system completely satisfies our requirements for high-quality filling results. For this reason, we have also decided to use the correspondingly adapted filling principle for our new KHS refillable glass bottle line as well.
*

CANNING TECHNOLOGY

The new KHS canning plant has a high capacity of 72,000 0.33-liter or 86,000 0.25-liter cans per hour. Heart of the line is an Innofill DMD mechanical can filler. What makes it stand out: rugged design, high capacity, best filling quality, extremely long service life, gentle filling, low CO2 losses, minimal oxygen pickup, fast changeover, correction of filling levels without stopping, high availability, high product savings. Praise from Managing Director Hamed: In addition to optimum machine technology, KHS always provides us with perfect consulting services. Im speaking of a partnership, which simply could not be better. And the Pepsi potential in Iraq isnt 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, KHS AG, Bad Kreuznach

INFOBOX

WEBSIDE www.pepsico.com CONTACT

In Iraq, PET means large-size bottles. Thats the orientation of KHS PET system technology for Baghdad Soft Drinks. The system processes both 1.5 and 2.25-liter PET bottles. The filling capacity is 12,000 1.5-liter or 10,800 2.25 liter bottles.
Special features:
*

Erhard Magin, Director for Africa,

A radial fan specially integrated into the air channel of the air conveyor reduces flow losses and saves energy.

Middle East, and Southern Europe Sales Region, KHS AG, Bad Kreuznach Tel: +49 (671) 852-2675 E-mail: erhard.magin@khs.com Meinhard Fischer, Sales Africa, Middle East, and Southern Europe, KHS AG, Bad Kreuznach Tel: +49 (671) 852-2631 E-mail: meinhard.fischer@khs.com

A natural healer invented a mixture some hundred years ago which later celebrated global success under the name Sinalco. Today after a pause of nearly three decades Sinalco is back in more than 50 countries. With an innovative keg solution, KHS is contributing to the promising growth of the brand.

A Brand Returns
Wonders never cease humanity has known that at least since Morcheebas hit song. A similar miracle is the skyrocketing return of Sinalco after the brand already spent a few decades in the retirement home of nonalcoholic beverages. But one thing after the other. Friedrich Eduard Bilz, along with priests Sebastian Kneipp and Johann Schroth the best-known German representatives of the health movement of the early 20th century, mixed a drink in the year 1902 from concentrates of seven tropical fruits and domestic produce. BilzSeele was his original name for this health elixir. Highly recommended for stomach, rheumatic, and lung ailments, said the bottle label at the time. Bilz obviously understood the tastes of the bulk of the population, because his marketing partner, Detmold factory owner Franz Hartmann, could

KHS keg technology involved in the global comeback of Sinalco

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.

barely keep up with production. In the first year, Hartmann had already sold three million liters of Bilz-Seele. Two years later, sales had reached 25 million liters.
THE FIRST TRIUMPH OF THE BRAND

In 1905, it was necessary to find a catchier name for the beverage. There were too many copycats on the market. The decision was made for the name Sinalco from the starting syllables of the Latin sine alcohole (without alcohol). The pleasant result: 80 million liters sold in the year 1906. The next year saw the beginning of Sinalcos global conquest with distribution to markets in South America and the Middle East. The Sinalco bottle got its unmistakable red dot in 1937, was available in 50 countries, and was bottled by 500 franchisees. The brand was so successful, its name became a generic

task+solution

42*43

internati onal rebirth.

2
* * * *

THUMBNAIL PORTRAIT: SINALCO

Th eS ina

lco s or igins d

ng ate back to the beginni

nt ce 0th e2 o f th

y, da To y. ur

th e

br

an di se njo yin g

100-year-old brand 1994: Relaunch by Hermann Hvelmann 2002: 1-liter refillable individual PET bottle Turnover: 2002: 41 million liters 2003: 100 million liters 2004: 164 million liters * Distribution to 50 countries * Restaurants: filled primarily in kegs

a na

tion

al an d

term those who wanted a soda pop in a restaurant ordered a Sinalco. This triumph held until the 70s, and then the brand started to fade. A series of new owners were unable to continue the success story.
THE SECOND TRIUMPH OF THE BRAND

It wasnt until 1994 when Hermann Hvelmann, managing owner of the Hvelmann beverage group, acquired the rights to the brand that the tide turned. In that same year, Deutsche Sinalco was founded, followed three years later by Sinalco International. In 2002, one hundred years after Bilz invented his refreshing mixture, Hvelmann brought the Sinalco bottle to market as a 1-liter refillable PET bottle in yellow brand crates and Sinalco started its second triumph. In 2002, Sinalco sold 41 million liters in Germany, and in 2003, it was

already 100 million. Hvelmann invested further in the brand, introducing the 0.5liter refillable PET bottle in 2004. The result: 164 million liters sold last year. And in the current year, Sinalco is now also available in non-refillable PET bottles. In the meantime, as in earlier days, Sinalco is again at home in more than 50 countries around the world. In 2006, Nigeria, Italy, Jordan, Egypt, Romania, Libya, Hungary, Sudan, Lebanon, and Cypress joined the list in rapid succession. The currently most significant foreign market is Serbia, where Sinalco holds a 30 percent market share. Only recently was a new Sinalco production operation opened, with an annual filling capacity of 200 million liters. Sinalco International grants franchise licenses for the use of brand rights to foreign bottlers, and supplies them with all

necessary ingredients, essences, and recipes from Germany. That ensures quality at the highest level. And that applies not only for the classic Sinalco Orange, but for all the flavors of the brand family including cola, lemon, citrus, diet orange, diet cola, diet lemon, diet citrus, cola mix, apple cider, forest fruit cider, and bitter lemon. With a 50 percent share of total sales, orange and cola are the leaders. Sinalco has been represented on the German market since 2003 by the mineral water brand Sinalco Aquintll. Under this brand, the company markets not only classical mineral water, but also flavored mineral waters and a wellness drink.
RESTAURANTS: KEG IS KING

An important component of Sinalcos success was and is restaurant sales. In 1970, its share of total sales of Sinalco in Germany was still 70 percent. That was a long time ago, but Sinalco is ready to add a new chapter to the old success story supported by a marketing cooperation with the Krombacher Brewery (since 2003). Last year, restaurant sales were 70,000 hectoliters. While in earlier years, bottles were usually delivered to restaurants, today 86 percent of the various Sinalco products flow into restaurants from 10- and 20-liter kegs.

A Brand Returns
CEO of Deutsche Sinalco.

Left Innokeg Till TRANSOMAT 5/1: One racking and five active washing stations. Center All from one source: Innopro Paramix CMX mixing system. Right After depalletizing: 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 Snchez, Manager of Production / Technology, Hvelmann Beverage Group; Nicole Fischermanns, Product Manager for Deutsche Sinalco, and Dr. Axel Drsser,

The keg combines the advantages of low space requirements, simple handling, and maximum hygiene, says Axel Drsser, business manager of Deutsche Sinalco, about the advantages of kegs to restaurants and large events. With a keg share of 90 percent, the 20-liter keg (and the premix variants, too) have the lions share of restaurant sales. For the postmix variants, the 10liter keg sees more use.
KHS OFFERS HIGH-TECH KEGGING EQUIPMENT

and exactly the flexibility we need, praises Francisco Snchez, production and technology manager for the Hvelmann Group. Flexibility is important, for instance, when kegs must be filled later for the international market. Because kegs also bring significant advantages over bottles for export due to simple, space-saving transport.
STATIONS OF THE KEG PLANT

Palletizing. At the present time, the kegs

Due to the great success of kegs, Sinalco recently invested in new KHS keg system technology, with a nominal capacity of 80 kegs per hour. A particularly important requirement of the new plant was its modular design. If growth in keg demand continues, this will allow problem-free augmentation of line capacity by a factor of three by integrating additional washing and racking lines. KHS offered us high technology

are still being palletized and depalletized by hand, but even now, the modular design provides the option of equipping the system with KHS robotic systems. Exterior cleaning. After depalletizing, the kegs enter the Innokeg AK 1 exterior washer. If additional washing and racking lines are integrated later, the Innokeg AK 1 can clean the kegs even more quickly with the same intensity. Interior cleaning. Interior cleaning is handled by the Innokeg Till TRANSOMAT 5/1. It

has five active cleaning and sterilizing stations, along with one racking station, and is thus ideal for soft drinks requiring special handling. Its intensive cleaning power ensures maximum microbiological safety. For us, the high microbiological safety is the most important aspect of the innovative KHS keg system technology, emphasizes Sanchez. The system cleans the interior keg surfaces and the riser pipe with a pulsed spray process. The subsequent hot water rinse removes any remaining cleaning agent adhering to the keg. Blowing the keg out with hot steam concludes the cleaning process, removes residual liquid from the keg, sterilizes it, and at the same time drives any remaining oxygen out ideal conditions for an optimum filling process. Likewise integrated are heat exchangers and culinary steam generators. While the heat exchanger heats cold water and feeds the media tank, the culinary steam

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

44*45

generator ensures that the hot steam inside the keg has a temperature of at least 125 degrees Celsius. This is required to ensure the needed sterilization effect. The entire cleaning process is monitored by a pressure sensor 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 Flow Control) process with volumetric flow control. In this process, pressurization to a pressure slightly above the CO2 saturation is enough. That reduces the consumption of carbonic acid in comparison with traditional filling solutions by up to 40 percent. The direct control of the filling process by a regulator valve on the product feed makes the DFC filling process extremely precise. There are neither product losses due to overfilling of the keg, nor any problems with underfilling. At the same time, product quality is ensured due to only minimal oxygen pickup. The filling process starts with a slow initial filling phase. The fast filling phase begins once the fitting is covered with product. An additional protection for the product being filled is provided by the filling velocity control. Installed upstream of the filling area are an Innopro Paramix CMX blending system and an Innopro KZE flash pasteurizer specially used for Sinalco apple cider. A heat exchanger cools the product filled to the predefined filling temperature. Full keg scale. The filled kegs then move onto the full keg scale. It detects empty or underfilled kegs and controls the automatic

rejection of these kegs. The correctly racked kegs are then palletized by hand and capped and the collar labels are applied. In this area, too, there is the option of extending the system by installing KHS robotics. Keg management system. Another highlight: The system is equipped with the Innokeg keg management system. It works like this: All Sinalco kegs have so-called transponders, which supply information to the Innokeg keg management system. Before a new keg is used, the central database stores data about the keg, such as its tare weight, volume, type and date of manufacture, fitting type, and the fitting manufacturer. All the data needed by Sinalco for efficient keg use can be stored in a data record this way. The filling system records the entire product life of each and every keg thats important for quality assurance at Sinalco. Before the washing process begins, the keg transponder is read out and, based on data such as market dwell time, number of fills, or the date of the last inspection, a decision is made whether the keg may be filled again. The result: only perfect kegs reach the line. And for a rejected keg, the operating personnel already know the reason for the rejection after a glance at the recording terminal. During the filling process, the database then stores the new information, such as the type of beverage, lot number, filling date and time, fill volume, and the condition of the media. The Innokeg management system also has a modular design and can be extended, for instance with another

module for marketing logistics. Then the transponder evaluation could also give some insight into the current location or the time the keg spends at the customers place of business.
READY FOR THE FUTURE

The increasing success of Sinalco in restaurants can now proceed perfectly, thanks to modern KHS keg system technology, predicts CEO Axel Drsser. Hermann Hvelmann shares that opinion. He is convinced by the growth of the Sinalco brand family on the German and international market: The Sinalco success story has only just begun. There is still a great deal of potential here. We will pursue our quality strategy just as consistently as we do the Sinalco brand strategy. Ready for the future.
Michael Schlegel, Central Product Support, KHS AG, Bad Kreuznach Wolfgang Augel, Central European Sales, KHS AG, Dortmund

INFOBOX

WEBSIDE www.sinalco.com CONTACT

Michael Schlegel, Central Product Support, KHS AG, Bad Kreuznach Tel: +49/671/852-2764 E-mail: michael.schlegel@khs.com Wolfgang Augel, Central European Sales, KHS AG, Dortmund Tel: +49/231/569 -1635 E-mail: wolfgang.augel@khs.com

Bad Driburger Naturparkquellen: Refillable PET plus glass

The Perfectionists
1
THE TASK

The Graf von Oeynhausen-Sierstorpff company group is working towards the complete health package, even in its seventh generation. And its doing that with perfection and a passion for top quality. For an individual refillable PET concept, KHS is once again the perfect partner: Supplier of a solution others wouldnt dare to try.

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 camera systems.

German poet Friedrich Hlderlin was full of praise: I used the bath a little and drank the wonderfully strengthening mineral water and I find myself extraordinarily fit as a result. The poet was in Bad Driburg, beloved for centuries for its spa and bath facilities. Today, the Graf von Oeynhausen-Sierstorpff Group still offers a true end-to-end package for the pleasure of guests and customers from near and far. From a business standpoint, the companys action areas are quite practical: Mineral springs, baths, and clinics. This complete health program, according to Marcus, Count von Oeynhausen-Sierstorpff, CEO of Operative Management Holding, represents a clear competitive advantage for his company group. The count sees the use of that advantage as a true challenge facing him, the seventh generation. The slogan: The truly new can only be built when history is honored.

Back to business: In the clinic department, the group has set its sights on sales of 55 million euros. In the baths department, the company has currently invested 20 million euros into the renovation of the park hotel and an expansion of the wellness area. Planned future sales: 10 million euros annually. The spring water department, including not only the Bad Driburger Naturparkquellen but also the Harzer Kristall Brunnen in Langelsheim (Lower Saxony), integrated into the group since 1994, should already reach 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. Welltested for Count Marcus, that is the quality of the mineral water, which is derived from its balanced, harmonic mineralization and low sodium content. New that is the step to modern styles of packaging. That

task+solution

46*47

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.

path to the refillable PET was planned to the smallest detail. Because the decision for the plastic bottle was made upon completion of market research. The refillable PET bottle for mineral water has an appropriately classical elegant design and a slender bottle shape. The connection between the familiar appearance of glass with that of the new PET bottle is due among other things to the aluminum cap, the champagne bottle type base, and PETs similarity to glass. Added to this: the socalled toasting f igures shown on Bad Driburger glass bottles. It is conspicuously integrated as a motif.
... AND ALSO RETURNABLE PET CRATES

Driburg logo is also everywhere on the crate even on the carrying handle that has been designed as a novel lengthwise soft-touch grip. In addition, the bottles are arranged in a circle around the carrying handle giving it another unusual visual impression. One can imagine just how much clever technology is behind all that. The count explains: We spoke with many providers of modern filling and packaging systems. Many of them told us it would be impossible to fulfill these requirements. But not KHS, here we felt understood and supported right from the start. In KHS, we are dealing with an innovative company who gets involve in customer desires and isnt afraid of new challenges.
A LINE FOR ALL EVENTUALITIES

began with the 0.75-liter GDB [Genossenschaft Deutscher Brunnen] refillable PET bottle for soft drinks. Martin Lehmann, CEO of Bad Driburger Naturparkquellen, reports: We started using this format as one of the first German spring water operations about a year ago, and offer our soft drinks Sport Aktiv, apple spritzer, and orange and lemon soda pop in these bottles. Today, 50 percent of our soft drinks are sold to the consumer bottled in PET.
... AND NOW THE 1.0-LITER REFILLABLE PET BOTTLE FOR MINERAL WATER...

Since every bottle needs a matching crate as the people in Bad Driburg well know the returnable PET crate had to be something very special. So that the consumer can recognize the Bad Driburger brand at the point of sale even from a great distance, the individual crate has a cutout on each side allowing a full view of the bottles. The bottles are then positioned in the crate in such a way so that the label communicates directly with the consumer. The Bad

This task is as follows: Integration of new packaging and labeling technology into an existing glass line in order to equip it for additional refillable PET bottle handling. And the capacity must be adapted to the filler output of 22,000 1.0-liter bottles per hour. The filler how could it be otherwise is from KHS. Lehmann says, This filler has excellent performance another argu-

THUMBNAIL PORTRAIT: BAD DRIBURGER

Similar successes can also be expected for mineral water bottled in PET. Since early 2006, the Bad Driburger Naturparkquellen have relied on a custom-designed 1.0-liter refillable PET bottle for mineral water, which has succeeded in fulfilling the expectations of a premium brand using targeted differentiation and selective attractiveness. The

* Family company in the seventh generation * Business areas: springs, baths, clinics * Naturparkquellen: 30 million bottles per year, of which: 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%), ACE Still, orange soda pop, and apple spritzer

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.

changing system. Bad Driburger is among the first companies in the world to implement this innovation.
A special feature of the format changing system:
*

* *

ment for the user of KHS technology for this project.

THE DESIRES OF THE CUSTOMER, PERFECTLY FULFILLED
*

The complete packing set is changed at the press of a button at the operator panel. A few manual activities still needed: Compressed air hose and electrical connectors must be disconnected from the previous packing set and connected to the newly installed one. Work that takes only a few seconds. The system picks up the gripper heads, centering frames, and lane plates one after the other, parks them, and then picks up the required new components to install them on the crater all fully automatically. Extremely space-saving solution allowing a number of packing sets.

even happier that KHS satisfied our plans perfectly even with regard to labeling. The labeling of the challenging 1.0liter refillable PET bottles and the various types of glass bottle is handled by the Innoket Roland 24/6. It processes up to 28,000 bottles per hour using the wet glue labeling technique. There are two labeling stations to apply back and front /neck labels.
Special features of the labeler:

Both the crater and the decrater are Innopack SP two-axis machines of the newest generation with the innovative KHS dry area module concept. Both are equipped with groundbreaking KHS innovation: the KHS format

The special features of the packing head:

INFOBOX

WEBSIDE www.bad-driburger.de CONTACT

Gnter Unkrig, Director, Central European Region, KHS AG, Dortmund Tel: +49 (231) 569-1602 E-mail: guenter.unkrig@khs.com Frank Schneidermann, Sales Germany, KHS AG, Dortmund Tel: +49 (231) 569-1104 E-mail: frank.schneidermann@khs.com

A sensor ensures perfect PET bottle alignment in the crates. Using luminescence detection, the sen* sor locates special printing marks on the labels of the bottles, which are invisible to the human eye. Quick, accurate turning of the bottles * is then performed based on the printing mark information. The bottles are also and this is * another challenge, which the packer head satisfies perfectly oriented in such a way that they are actually interlaced in the crate. This results in the desired circular positioning around the handle. Plant Manager Lehmann comments: We know our special needs. Thats why were
*

Maximum flexibility using the VarioDrive electronic bottle turret control system. The bottle turret, motor, and electronic * equipment form a single unit and communicate directly with one another. Four camera systems, each coupled * with a lighting unit, ensure exact label application. A computer algorithm evaluates con* trast differences, comparing the actual and expected states of the toasting figure. A bus system then communicates individual correction rotations directly to each VarioDrive, which executes them precisely. The result: the circular cutout in the neck label precisely surrounds the toasting figure. At the same time, the lettering on the front label is aligned with the center of the toasting figure, along with the correspondingly perfect application of the back label. This is how KHS uses the latest in technical solutions to provide perfection down to the last detail. Marcus Count von OeynhausenSierstorpff and Martin Lehmann agree. Just as they agree on how convinced they are that the success story of their company will continue.
* Gnter Unkrig, Director, Central European Region, KHS AG, Dortmund Frank Schneidermann, Sales Germany, KHS AG, Dortmund

technology+innovation

48*49

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 teams 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.
Why not come right to the point? The new KHS bottle washer Innoclean SEC provides the best cleaning results, ecological and cost advantages, is extremely compact, and can easily be integrated into existing systems. At the same time, it sparkles with all the technical highlights from the area of KHS high-performance bottle washing technology. In short: High-tech from the finest for the midsized beverage industry. The Innoclean SEC is specially designed for the cleaning of glass bottles at a capacity of 6,000 to 24,000 bottles 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 is small, but its multitalented.
TWELVE HIGHLIGHTS: ENORMOUS ADVANTAGES IN THE FIELD The system also offers some highlights

that will bring you significant advantages in practical application. A quick overview:

for all drives without mechanical connection / mechanisms are decoupled / intelligent control / fast data transfer and exchange with servo converters in drives / gentler movements / lower replacement part and maintenance costs / preventive maintenance / pushbutton conversion when switching bottle types / manual transfer to bottle discharge eliminated for product changeover / short reconfiguration times all without stopping the cleaning process.

Triple-i-Drive integrated. Synchronous cycles

The new Innoclean SEC

INFOBOX WEBSIDE www.khs.com CONTACT

Bernd Molitor, Competence Center Manager, Cleaning Technology, KHS AG, Dortmund Tel: +49 (231) 569-1573

E-mail: bernd.molitor@khs.com Jan-Karl Nielebock, Product Manager of the Cleaning Technology Competence Center, KHS AG, Dortmund Tel: +49 (231) 569-1340 E-mail: jan-karl.nielebock@khs.com

tles / Jetting is always a combination of Triple-I-Drive with classical full-stream spraying pressure of the spray jet shooting vertically into the bottle always remains constant.

New type of spray combining Triple-i-Drive with classical full-stream spraying the pressure of the spray jet shooting vertically into the bottle always remains constant bottle speed slowed while spray directed into the bottle speeds up when spraying between bottles.

New Drivejet spray.

In comparison with traditional steel carriers, the energy-saving carriers use up to 15 percent less heat, as well as up to 20 percent less water / Weight reduction between 20 and 25 percent / Full load still supported.

Energy-saving bottle carriers standard.

In the caustic bath, calculated flow in combination with submerged caustic flushing / Immediate removal of labels loosened earlier / Pulping of the label paper effectively reduced / Upper caustic flushing removes remaining labels / Outstanding label removal rate (comparable to high-performance range)

High label removal rate.

First residue removal, then pre-soaking / Preheating of the bottles / Soaking of dried-on beverage residue (e.g. fruit fiber, yeast residue) / Complete filling of bottles / Removal of beverage residue even before the caustic treatment. Pre-spraying removes (drinking straws, cigarette butts, lemon slices, etc.) from the bot-

Pre-soaking and pre-spraying standard.

Peak value / For 0.5-liter bottles, about 8 milliliters per bottle / Up to 25% lower cleaning agent consumption.

Minimum caustic carryover.

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

Optional full stainless steel version.

technology+innovation The new Innoclean SEC

50*51

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.

/ With stainless steel, no corrosion problems caused by

residual water / Long life.

External heat exchangers redesigned for heating of caustic bath / Plate heat exchanger ensures optimum heat transmission / Regulation of condensate side increases efficiency of steam use / Power consumption reduced by up to 5 percent / Furthers compact design.

Heat exchanger saves energy.

160 ml of fresh water per 0.5-liter bottle an excellent value for this performance range. Cascading water circulation, just as in high-performance range / only one pump size (standard until now: up to three different pumps).

All functional components (for instance, drives, pipelines and pumps, filters) on machine side only / For smaller spaces, higher machine performance with same bottle handling time / Equipment standardized / Four widths and two lengths available / Machine is one piece complete with piping and wiring; tested.

Compact design.

As for KHS high-performance cleaning, the microbiologically unsafe condensation of vapors on cold exterior surfaces of the discharge is prevented by heating the critical media surfaces / Also integrated: vapor exhaust (avoids the suction of contaminated air into the machine head section) / No danger of biological reinfection of cleaned bottles.

11

Maximum microbiological safety.

Operation using color monitor / Major functions are automated / Plug-and-play startup / Manual sanitizing.
Result

12

Easy and straightforward operating.

After caustic bath, recooling of bottles and rinsing of cleaning caustic from bottles and carriers / Four spray zones standard / Full-stream spray with variablecycle drive speed. Special feature: fresh water spray stops once the bottle leaves the spray stream this keeps the consumption of fresh water as low as possible / Energy-saving bottle carrier ensures good washing behavior with minimum water consumption and low heat carryover / Maximum of

10

Fresh water consumption minimized.

Considering all aspects the focus of all technologies Made by KHS is always on customer benefit. The first machine is sold to Herbsthuser Brauerei Bad 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

From the outside, there is nothing to be seen but inside they are extremely complex: Modern filter systems improve the beer product for the consumer. KHS is in on it right from the beginning with its filtration technology. 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.

Technical terms in practice

Filtration: Makes
The exact date that beer filtration started cannot be determined. However, it can be justifiably maintained that the development of modern filtration technology began in June 1878 with the invention of the universal fast filter by Lorenz Albert Enzinger. The special feature of this filter was the use of ready-pressed filter sheets for the first time. Filtration is the last stage in the beer making process before the beer is bottled and sold. The effect achieved by natural clarification is improved primarily with the help of filtration in order to be able to offer the consumer a bright, clear, and non-perishable beer. With filtration, this task not only requires the exact knowledge of all determining factors, but also the exact control of the filtration process. But filtration must also be optimum for economic reasons.
THE PRINCIPLE THE FILTER EQUATION

Perfect
is called the filtrate and the solid material separating onto the support sheet is called the filter cake. Ideal cake filtration can be described using Darcys equation. Strictly speaking, this only applies to laminar flow through a porous, incompressible filter cake and states that the volume flow is proportional to the pressure difference p applied between the top and bottom side of the filter and is inversely proportional to the dynamic viscosity of the filtered liquid . The higher the applied pressure difference and the lower the viscosity, the higher the filtration volume flow per unit area. Furthermore, a factor described as the filtration resistance R is included in the equation. The higher this resistance, which opposes the liquid flowing through the porous cake, the less filtrate is produced per unit time and unit area. In turn, the filtration resistance R is made up of the cake resistance rk and the resistance of the support sheet ro.

Beer filtration involves the separation of liquid and solids. The problem is one of a liquid flowing through porous bodies. Here, the filter cake holds back the substances that cause turbidity. This occurs predominantly due to a straining action, but also partially due to adhesion and /or adsorption depending upon the composition of the filter aid. In filtration especially, the clarified phase

R = rk + ro

technology+innovation

52*53

PRECOAT FILTRATION

Filter medium is applied to a highly permeable support layer (metal sieve, filter cartridge, cellulose support sheet). The surface is continuously renewed by dosing permanently with kieselguhr. There is significant scope for controlling the filtration depth through the selection of filter aids with different degrees of fineness. The filtration duration can be influenced by using different amounts of kieselguhr. Kieselguhr is the main filter aid used, but Perlite, a specially conditioned ground volcanic rock, is also used. An alternative method of precoating, dosing and preparing the kieselguhr mixture is often necessary. KHS has the right filter for every application: The Getra Eco is provided as a cartridge filter for pre-clarification of products. If stabilization is required, a horizontal mesh filter, the Kosmos, can also be used in addition to the Getra Eco. A kieselguhr frame filter in the Orion range has proved its worth in thousands of ways. Post-filters are also available. These are known as Corvus and are ranked with the group of fine filters and membrane filters. The latest knowledge is leading to kieselguhr-free filtration with cellulose mixtures as used by KHS in the new KOMETRONIC filter system. Here, the filtration principle is as in any precoat filtration and 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 importance and gives the built-up layer its strength. In the next step, a finer filter aid is applied, thus building up * the filter cake. When precoating is complete, the actual beer filtration begins * with the continuous dosing of the filter aid to the cloudy unfiltered product.

The relatively large yeast cells can sometimes act as a positive filter aid when building up the filter cake. If the amount of yeast is too great, however, this has a negative effect and blocks the filter cake.

THE FILTER MODELS AND COMBINATIONS

The oldest, but even today still most widely used, precoat filters are frame filters (ORION) with frame sizes between 40 x 40 cm and 120 x 120 cm. The work involved in removing the kieselguhr and in cleaning is relatively high; rinsing, sterilization and precoating can however be automated. Bowl filters such as are used in the Getra Eco are more suitable for automation. These filters have an hourly capacity of 5 hl /hm2, although due to the higher load per square meter, their service life is lower than that of frame filters. After precoating, however, bowls can be purged with carbon dioxide thus reducing the beer loss and undesirable mixing with water. Kieselguhr is removed automatically 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

INFOBOX

WEBSIDE www.khs.com CONTACT

Dr.-Ing Hartmut Evers, Laboratory and Technology Center Manager, KHS AG, Bad Kreuznach Tel: +49 (671) 8522252 E-mail: hartmut.evers@khs.com

Technical terms in practice

Filter cake build-up

Filter, textile, sieve, or cartridge

Filtrate Pre-coating with kieselguhr

Filtrate

Filter cake with dosing

Bridge building in cake-forming filtration, precoating, and dosage

that they can be fully automated, bowl filters are more economical than filter presses. The used kieselguhr is discharged as a thick paste or in semi-solid form, reducing wastewater contamination. The latest filter system is the KOMETRONIC with horizontal filter elements and central infeed. This filter has many special features and these are only listed briefly here. A special presentation of the filter will be provided in a later issue.
ADVANTAGES AND SPECIAL FEATURES OF THE KOMETRONIC
* * * * * * *

* *

Significant savings in operating costs Low maintenance costs and easy servicing

SUMMARY

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 sanitizing Regeneration of filter medium

Bacteria: Yeast: Kieselguhr: Fine Medium Coarse

1-4 m 1-5 m 2-10 m 10-20 m 20-40 m

Kieselguhr filtration has enjoyed great success in Germany since 1950. Kieselguhr was used for the first time in England from the middle of the 1930s, initially as an additive to the mass. Actual kieselguhr filtration for beer developed in the U.S.A., from where it came to Europe. However, disposal has become a major problem in past years. As a result of rapid cost increases in the disposal sector, fees of up to 500 euros per ton of wet kieselguhr are no longer a rarity at special waste disposal centers. This developing trend has triggered activities in various directions. These relate to the conditioning of used kieselguhr using presses, drying, heating, and sifting or by treating with caustic and acid. Other research is concerned with the abandonment of kieselguhr as a filter aid. In the search for ways of replacing kieselguhr, a return was made at the end of the 1990s to the regeneratable filter mass. This resulted in the development of a new filtration principle, which brings advantages by combining the clarifying filtration and stabilization sections to form one process step with complete regeneration of the filter aid. This development was an inducement for KHS to adjust to the new circumstances, and to further enhance and market the filter system that had already been developed in the 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

Filter sieve: 25-55 m

Guest at KHS

54*55

Left Kaiserburg with Albrecht Drers House: Rauchbier [ smokebeer ] can be obtained right next door in the Gasthaus Schlenkerla Top The Church of Our Lady with the Schner Brunnen [Beautiful Fountain] in the foreground. Turn the ring and wishes will come true.

Welcome to
The BRAU Beviale in Nuremberg has developed into an international trade fair and KHS welcomed customers from all over the world again this year. We hope you were among them. If not, perhaps youll have the opportunity of getting to know the city of Nuremberg better the next time or during your next visit to Germany. Nuremberg is famous for its cultural assets, the town center lying within the old town walls with its historical churches, squares, memorials and the 11th-century Kaiserburg towering over everything. Should you ever have the chance to tour this beautiful city on your own, it is best to start your tour opposite the Nuremberg Central Train Station with the Tradesmans Court and its antique workshops nested in among 12th century pubs. From here, go towards the central market via the Breite Gasse shopping avenue to the Ehebrunnen, then past the Church of St. Lorenz (built in 1274) over the leisurely flowing Pegnitz to the Church of Our Lady. From the bridge, you can see the Heilig-Geist-Spital jutting into the river. The Schner Brunnen with its wishing ring stands in the central market place with the Church of Our Lady, where the Christmas market begins on the first day of Advent. Turn the ring, and your wishes will come true. I hope so, at any rate. But now its high time for a little snack. If you are hungry for an original Nuremberg Bratwurst, you should visit the largest restaurant of its kind in the world, the Bratwurst Rslein. Or walk another 100 meters past the St. Sebaldus Church dating back to the year 1230, across Albrecht-Drer-Platz and you will find yourself in the middle of the castle quarter. Here stands the Gasthaus Schlenkerla by Albrecht Drers House with its world-famous Rauchbier. King Juan Carlos, soccer star Kaiser

Nuremberg
Georg Herrmann, Senior Installation Inspector, KHS AG

Franz Beckenbauer, and also commoners such as Helmut Kohl, Dietrich Genscher, and Jacques Chirac have dined only a few meters further in the Sudhaus. My special tips in the castle quarter are the Alte Kchn (in existence for 400 years) and the Rittersaal-Keller in the Burghotel. Here, you will be spoiled with Franconian specialties and the flair of the surroundings. Anyone just wanting something to drink should seek out the little bars and pubs below the castle. And on the way back to the hotel, a small nightcap in the Kon-Tiki or the Zauberberg is almost a must. Hope to see you soon in Nuremberg!

Tradesmans Court: 12th century workshops and pubs

Adresses
KHS AG Juchostrasse 20 D-44143 Dortmund, Germany Tel +49 (231) 569-0 Fax +49 (231) 569-1541 Planiger Strasse 139-147 D-55543 Bad Kreuznach, Germany Tel +49 (671) 852-0 Fax +49 (671) 852-2411 Enzingerstrasse 139 D-67551 Worms, Germany Tel +49 (6247) 97-0 Fax +49 (6247) 97-3215 Ruwoldtweg 14 D-22309 Hamburg, Germany Tel +49 (40) 63703-37100 Fax +49 (40) 63703-37150 Boschstrasse 1-3 D-47533 Kleve, Germany Tel +49 (2821) 503-0 Fax +49 (2821) 26110 Am Kirchfeld 3 D-34454 Bad Arolsen, Germany Tel +49 (5691) 8909-0 Fax +49 (5691) 8909-15 Kapellenstrasse 47-49 D-65830 Kriftel, Germany Tel +49 (6192) 491-0 Fax +49 (6192) 491-144 KHS METEC GMBH Industriegebiet Scheid 16 D-56651 Niederzissen, Germany Tel +49 (2636) 9746-0 Fax +49 (2636) 9746-45 E-mail: info@metec-gmbh.de KHS UK LTD. Unit 6 Monkspath Business Park, Highlands Road Shirley Solihull, Great Britain West Midlands B 90 4NY Tel +44 (121) 713-6901 Fax +44 (121) 745-5306 E-mail: info@khs.com KHS USA, INC. 880 Bahcall Court Waukesha, WI 53186, U.S.A. Tel +1 (262) 797-7200 Fax +1 (262) 797-0025 E-mail: mark.arrant@khs.com 5501 N. Washington Blvd. Sarasota, FL 34243, U.S.A. Tel +1 (941) 359-4000 Fax +1 (941) 359-4043 E-mail: randy.uebler@khs.com KHS PACIFIC PTY. LTD. P.O. Box 378 1-3 Freight Road Tullamarine, Vic. 3043, Australia Tel +61 (393) 35-1211 Fax +61 (393) 35-1331 E-mail: info@khspacific.com.au KHS ASIA PTE. LTD. 25 International Business Park # 3-15/19 German Centre Singapore 609916 Tel +65 6560-9313 Fax +65 6560-9910 E-mail: info@khsasia.com

About
PUBLISHER KHS AG, Dortmund EDITORS Friederike Arndt, Maternus Gemmel, Manfred Rckstein, jj-media, Cologne GRAFIK Konzeption+Design, Trawny / Quass von Deyen, Cologne Layout: 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, Gnter Unkrig TRANSLATIONS Fachbersetzungen 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 Nrnberg, Stieglbrauerei zu Salzburg GmbH, vario images / Christian Ringbaek, Unternehmensverbund Karlsberg KHS journal offers young students and graduates of the University of Applied Sciences in Dortmund and Mnster the opportunity to put their photography talents into practice. This information is non-binding. Only the technical specifications of our quotes are determinative with regard to design and scope of delivery. Subject to design modifications.

E-mail: info@khs.com

KHS worldwide: You will find further addresses and contacts at

www.khs.com

30 1992-01-984 /2 1106 GW