Energy savings and automation: KHS demonstrates next-generation filling solutions at BrauBeviale 2019

19 Nov 2019 --- Filling and packaging systems manufacturer for the beverage, food and non-food industries KHS showcased several advanced packaging concepts during BrauBeviale 2019 in Nuremberg, Germany. Notably, the German supplier demonstrated its next-generation Innofill Glass DRS filler, which “sets standards in sustainability, flexibility and automation.” KHS also presented its FormFill technology, which combines the forming and filling of plastic bottles in just one process step and is now undergoing final acceptance for operation before the end of 2019.

At BrauBeviale, the systems supplier presented the Innofill Glass DRS bottler in what is known as its ECO variant to the public for the first time. The DRS ECO is distinguished by its lower energy consumption (which is reduced by up to 20 percent), with CO2 emissions falling by as much as 50 percent. Thanks to digital networking and monitoring, the glass bottle filler also provides optimum product quality and increased line availability.

“Many bottlers are expanding their portfolios. We are seeing an increased demand for glass containers in particular,” says Manfred Härtel, Filling Product Manager for KHS. “With the Innofill Glass DRS ECO we provide pioneering filling technology which meets the growing market requirements for flexible and efficient production processes.”The Innofill Glass DRS ECO combines the tried-and-tested KHS filling system with digital, resource-saving technologies.

The new KHS system bottles beer, mixed beer beverages, cider and soft drinks. It can fill containers holding between 0.1 and 1.5 liters, processing up to 80,000 0.33-liter bottles an hour, for instance.

The KHS glass filler also boasts a number of intelligent digitalization and automation technologies. The DIAS diagnostic assistance system, for example, monitors the entire filling process.

With its new generation of fillers, KHS is pushing ahead with a project to standardize its entire product spectrum. “We plan to give all our fillers the same modular machine structure and as many identical parts as possible in the future,” Härtel states. “This means that our customers can quickly and flexibly retrofit their base machines with additional components, depending on how the beverage market and their own production policies develop. This gives them greater security for the future.”

KHS FormFill in final acceptance
Following the presentation of the future-oriented FormFill concept in 2017, the first KHS FormFill system underwent final acceptance in time for this year’s BrauBeviale. The new KHS technology combines the forming and filling of plastic bottles in just one process step. Operators benefit from considerable energy savings and a smaller machine footprint.With KHS FormFill, bottlers can form and at the same time fill containers made of PET or rPET on a single machine.

With FormFill technology, KHS combines two processes that were previously separate. On present machinery, two individual function modules stretch blow mold the PET preform and then fill the resulting bottle in separate stages. With KHS FormFill, bottlers can now form and at the same time fill containers made of PET or rPET on a single machine.

The system takes up 40 percent less space compared to standard stretch blow molder/filler blocks. The time saved by the form/fill wheel has enabled parts of the capping process to be integrated at this point. This then results in the machine being able to prevent product loss during container conveying.

The current tried-and-tested system has been configured for still water. However, the technology is just as suitable for liquid soap and laundry detergent and a whole range of hot fill applications. The current container formats vary from bottles with a volume of 500 milliliters to those holding 1.5 liters.

“For the market launch in the coming year we’re focusing on outputs of 12,000 to 24,000 bottles maximum per hour,” notes Frank Haesendonckx, Head of Technology for KHS Corpoplast. KHS subsequently aims to also provide this technology for the medium and high-performance ranges. “Here, we are engaging in active discussion with our clients so that we can also satisfy specific customer requirements.”

With the latest generation of the KHS glass filler, users save up to 50 percent in CO2 emissions and a maximum of 20 percent in energy.“Taking all of the savings into account, FormFill consumes up to 60 percent less energy compared to a current stretch blow molder/filler block,” Haesendonckx adds.

KHS develops an intelligent filling valve in the DnSPro research project
On the second day of BrauBeviale, KHS turned its attention turned to the future of filling, introducing a new, self-learning filling valve. The system optimizes the production process with the help of artificial intelligence and considerably reduces the time and effort required for operation and maintenance. The feasibility of this flexible valve has been verified by KHS in the DnSPro research project.

“To date, depending on the beverage and container, around 20 different types of filling valve are used,” says Jochen Ohrem, Expert of R&D Management for KHS in Bad Kreuznach, Germany. “The beverage industry is increasingly calling for versatile filling systems. Digitally networked line and machine systems are also in high demand.”

KHS is aiming to significantly push these changes which is why the Dortmund systems provider has taken part in the DnSPro research project alongside six other partners. Their common goal is to develop a self-learning filling valve with which beverage producers can fill all liquids into all existing types of container. This would do away with the need for manual conversions and the effort required for operation and maintenance would be greatly reduced, Ohrem explains.

“We developed cyber-physical systems for this purpose, with the help of which the valve can determine how to best fill a certain beverage into a certain container as quickly as possible,” Ohrem continues. The filling process is analyzed with the assistance of a camera. This continuously monitors the inclusion of bubbles and foaming to prevent excessive foaming and thus product loss.KHS developed a versatile, self-learning filling valve during the course of the DnSPro research project.

With the help of microcontrollers and the camera’s evaluation electronics, the filling valve is opened to varying degrees by a stepper motor depending on the fill level. “The focus was on ‘learning’ a number of skills: self-configuration, analysis, self-diagnosis and, ultimately, self-optimization,” explains Ohrem.

The future objective is to increase flexibility and energy and resource efficiency in production through the application of an autodidactic system of artificial intelligence. For the first time at BrauBeviale, KHS presented the key data on this intelligent filling valve, which “fully satisfies” all of the previously specified project requirements.

Basic Line Monitoring: Web-based app increases line efficiency
With Basic Line Monitoring KHS, offers its customers a web application which supplies data to assess the efficiency of a production line. It is based on the modular Innoline MES production management system. The module’s intuitive and convenient user interface simplifies production monitoring. This boosts line efficiency and provides safe access to performance data also outside the customer’s own network.

Innoline MES is a software program that is tailored to meet the requirements of the beverage industry and provides greater transparency in line monitoring and order management. It also performs control functions on the line. The IT system includes six modules with various functions that can either operate as stand-alone units or be used in combination. 

Conversion instead of new investment
KHS machines boast strong reliability and are often in use for many decades. Yet even after a very long period of operation, it is not always necessary to reinvest. In essence, the technology on bottle washing machines, for instance, has not changed.

For many years, the systems supplier has thus provided a variety of conversion packages, which bring older machines up to date. This not only gives bottlers benefits in economy and efficiency but also cuts down on the use of resources and therefore helps to protect the environment. German beverage manufacturer Aqua Römer is one such customer to profit from a machine makeover.A bottle washer is one of the biggest machines on a line. For several years, KHS has provided a variety of conversion packages, which bring machines into line with the technical and ecological state of the art. 

With its capacity-dependent freshwater control option, KHS installs a control valve to adjust the water supply, considerably reducing consumption at a lower machine capacity. Older equipment can also be fitted with KHS’ Liquid Efficiency Spraying System (LESS). This is an electricity-saving function for spray pumps which minimizes the spray pressure during downtimes. As a result, the machine uses 80 percent less energy in standby mode. Optionally, a flexible spray pressure also enables light glass or PET bottles to be processed.

In other KHS news, the supplier launched the first recyclable juice bottle made of 100 percent recycled PET (rPET) at the K 2019 show in Düsseldorf, Germany, in October.

Also, following the opening of its headquarters in Shanghai in 2014, KHS recently announced its intention to build a new plant and service center in Kunshan, China, in a bid to set new standards for company productivity and sustainability. With a total investment of around €10million, the new factory, around 10,000 m² large, will make engineering, production, logistics and service more efficient.

Edited by Joshua Poole