SOLUTIONS FOR THE FRUIT JUICE INDUSTRY

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2 you care for the content. we care for the filling and packaging. As flexible as your products: Solutions for tomorrow s markets While you take care of the further development of your variety of products, the experts from KHS ensure you get the ideal filling and packing processes regardless if your products are to be filled and packed in bottles, cans, kegs, or other types of container or pack. The company KHS The roots of KHS date back primarily to the foundation of Holstein & Kappert GmbH in Dortmund, Germany in 1868 and Seitz-Werke in Bad Kreuznach in Today, KHS is a manufacturer of filling and packing systems with one of the highest levels of performance and sales worldwide. With its more than employees working in 14 production sites, KHS delivers complete systems and attractive individual solutions to more than 130 countries around the globe. KHS is a partner you can rely on. A company that understands the requirements of customers and, based on longstanding experience, offers the best prerequisites for ensuring your market success for the future. KHS the fruit juice specialist As a supplier of complete systems and machines, KHS offers filling systems optimally tailored to the requirements of the fruit juice industry. This is partially based on internationally recognized, patented developments such as aseptic cold filling in PET bottles. Technologies of this kind ensure that the natural taste and unadulterated flavor of fruit juices are retained. The equally innovative long-tube filling system prevents the buildup of fruit pulp from pulpy products. And when it comes to keeping the filler hot at a certain temperature, or safe CIP or SIP sanitizing and disinfection processes, the versatile and optimally integratable solutions from KHS are reliable enhancements to your processes. With its computer-controlled, pneumatic, combined KHS Innofill DNRV filling system, KHS additionally offers, for example, capabilities for pressurized and normal pressure filling of plastic bottles including a volumetric filling process and automatic change-over option for changing bottle mouth sizes. Conventional lifting elements are no longer necessary and the filling valves are sealed for CIP sanitizing fully automatically using swivelable rinsing plates. The KHS Innofill DNRV is thus virtually predestined for bottling under aseptic conditions. KHS the pioneer in ACF technology KHS installed its first ACF system in the early 1990s, and has many years of experience in this field. By supplying both the modern dry process for sterilization of bottles and sealing with H ² O ², and the traditional wet process with peracetic acid, KHS offers the right solutions for bottling the most sensitive of fruit juice beverages in plastic bottles for example. The ACF concept additionally offers maximum flexibility for bottling noncarbonated as well as carbonated beverages. A colorful mixture of fruitful ideas The fruit juice market is a lively and colorful market where wellness and healthiness, fun, and enjoyment determine the trends. Fruit juice spritzers are the big sellers. High-quality fruit juices and nectars have also become a permanent part of wholesome nutrition and are being put on the market in the future in an ever-increasing variety of mixed drinks and convenience packaging. The ACF technology from KHS plays a major role in optimally satisfying customer demands for all-natural products while retaining the natural flavor and aroma as well as the color of beverages. And since there is no need for preservatives, the health aspects are also taken into account. 2

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4 THE RIGHT MIXTURE OF TECHNOLOGY AND KNOW-HOW: HOLISTIC SYSTEM SOLUTIONS FROM KHS KHS a reliable partner in the fruit juice sector KHS supplies exceptionally economical and costeffective machines and systems for process engineering equipped with proven machine technology and know-how well thought out down to the last detail. The recipe for success involves providing tried and tested, high-quality, hygienically designed, stainless steel process engineering components that obtains a high level of product safety. Small details such as circular tube sections of which all base frames of the process engineering components are made, which entirely eliminate the build-up of deposits, provide decisive benefits with regard to maintaining sanitary conditions and increasing product quality. All in all, seemingly insignificant details in the overall system in particular are frequently crucial items in enabling our customers to gain competitive advantages. KHS offers state-of-the-art technologies ranging from process engineering through sanitizing and filling to labeling, packing, and palletizing that are highly regarded by leading fruit juice pro- ducers around the globe. The intensive cooperation with renowned technical institutes, associations, and educational facilities and the knowledge gained from this work has enabled KHS to consistently consolidate its technological lead and expand product portfolio. Moreover, with activities of this kind, KHS also assumes the responsibility for promoting and educating young talent further in the beverage sector thereby making design engineers as well as beverage technicians fit for the future. The whole spectrum of proven solutions Get to know KHS whole range of machines, systems, and services for the fruit juice bottling: Process engineering solutions Rinsing/cleaning Filling Capping/crowning Pasteurizing/recooling Labeling Inspection technology Packing Palletizing Keg processing Process engineering solutions We offer the fruit juice branch of industry a complete line of process engineering equipment ranging from concentrate and juice handling through blending, deaeration, and flash pasteurizing up to and including CIP/SIP sanitizing technology. By carefully selecting the components and the quality of materials in conjunction with hygienic design, KHS meets maximum process engineering standards where hygiene and safety are concerned. Our all-from-one-source concept enables us to ensure an exceptionally economical process flow. Rinsing/cleaning Be it dry or wet treatment, KHS cleaning technology ensures high product safety in all instances. Using bath-version bottle washers for refillable bottles generally eliminates the need for installing a rinser. The future-oriented KHS Innofill FR- EM single-channel rinser for blowing all particles out of PET bottles with ionized air, for example, is used for one-way PET. The modular KHS Innoclean bottle washer is available as a single- end or double-end machine equipped with a var-iable drive concept designed to process glass and PET/PEN containers. KHS offers a high precision drive concept for high-performance bottle washing with its Triple-i-Drive technology where each motor is equipped with a variable frequency inverter and an actual value transducer. Filling KHS supplies reliable developments with its innovative filling systems that are suitable for filling bottles made of glass and plastic in addition to cans and kegs. All systems offer high-accuracy dosing, efficient use of raw materials, as well as high flexibility and fast changeover capabilities thereby providing maximum investment security and future proofing. This also applies to the ACF processing method for microbiologically sensitive products and ultra-clean filling (UCF), the practice-oriented alternative. Capping/crowning KHS also relies on holistic solutions when it comes to capping and crowning. Whatever the 4

5 requirements, KHS offers the fruit juice sector the appropriate capping/crowing systems to guarantee high product quality even when the products are packaged in addition to maximum convenience for consumers. Pasteurizing/recooling Bottle recoolers equipped with an active heat retention zone or an upstream headspace sterilizer are for bottling juices or for hot filling. Bottle pasteurization is also possible as an alternative. Labeling Regardless of the container shape, the type of material you would like to use, or which advertising accents are needed, KHS offers the fruit juice trade a broad spectrum of possible combinations and a variety of labeling technologies. Inspection technology Today, cutting-edge inspection equipment for quality assurance is a basic prerequisite for ensuring high product quality. KHS offers comprehensive solutions for this purpose that meet all cus- tomer requirements ranging from object inspection through production code and label checking up to and including fill level and leak checking. Packing New consumer trends, new marketing strategies, new environmental regulations, stiffer competition, and increasing cost-consciousness that are increasingly governing the market, require even greater flexibility in packaging. Within the scope of its versatile, modular base concept, KHS offers advanced technologies that can be individually tailored to your needs and consumer demands of tomorrow. So that you benefit from the best packaging solution at all times from both a technical as well as an economical standpoint. Palletizing KHS palletizers and depalletizers are modular in design offering a maximum of flexibility at a minimum of operating costs. Regardless if for cartons, trays, or crates, whether refillable or nonrefillable packaging, with tried and tested bases comprised of frames, columns, as well as servo and frequency-controlled drives, KHS offers the right palletizing unit for every task. The advantage: Plenty of flexibility for precise system planning and efficient operation. Keg processing As a market leader, KHS offers ideal solutions for highly efficient washing, sterilizing, racking, and handling of standard kegs in the fruit juice industry. State-of-the-art DCF racking technology reduces the volume of counter-pressure gas as well as the O ² pickup. The result is an optimally controlled racking phase with constant fill levels. KHS delivery program includes individual machines and complete racking systems that guarantee considerable competitive advantages. The new hygienically designed racking head for cold aseptic keg racking, for instance, that guarantees adherence to the shelf life and retains the flavor stability. Look for further information in the Internet at Products & Solutions.

6 ULTRA-MODERN TECHNOLOGIES FOR FUTURE JUICE TRENDS: KHS RELIES ON MODULARITY COUPLED WITH MAXIMUM RELIABILITY Versatility is the recipe for success The trends in the fruit juice branch of industry demand an ever-increasing variety of bottle sizes, shapes, and materials and flexible, efficient solutions. With more that filling systems installed worldwide, KHS is one of the leading suppliers. In dialog with our customers, we concentrate on finding reliable solutions to specific tasks in order to be able to produce systems offering highest possible efficiency over their entire service life. KHS puts innovations into bottles Our computer-controlled probe filling systems are designed for bottling a widest range of beverages in glass and plastic bottles. They are used primarily as normal pressure filling systems (NRF) or as combined pressure/normal pressure fillers (DNRF). Filling tube systems using the bottomup filling method provide low-foam bottling of hot and cold filled juices, as well as carbonated and non-carbonated products. The fill level is measured directly at the filling tube by a probe thereby enabling exceptionally exact fill levels and central fill level adjustment at the operator terminal. Volumetric filling systems are mainly used to fill plastic bottles. Combined pressure and pressureless filling systems are also available. Of particular mention at this point is the DNRV filling system equipped with automatic format changeover for two bottle mouth sizes and automatic CIP tanks. Future-oriented ACF technology The microbiological sensitivity of a product is determinative in choosing the filling method. Either aseptic cold filling (ACF) or ultra-clean filling (UCF) is used. The decision must be made right from the beginning due to the considerable difficulties involved in converting to the other method later. The aseptic cold filling process retains the natural flavor and aroma as well as the color of every beverage and since there is no need for preservatives, the health aspect is also taken into account. For this reason, the ACF process from KHS is well-suited for the filling of the most sensitive of beverages in plastic bottles. Moreover, our ACF concept offers maximum flexibility and capabilities for bottling non-carbonated as well as carbonated beverages. The UCF filling method in contrast, is used to cold fill products in glass and refillable and non-refillable PET bottles under extremely low-germ atmosphere conditions free of beverage-contaminating germs. Unlike the ACF method, which involves the concept of completely sealing off a clean room from the outside, the rinser-fillercapper of the UCF method is not enclosed in a hermetically sealed glass isolator. The UCF method is sufficient for normal beverages and fruit spritzers while the ACF method meets the higher hygiene and gentle product handling conditions required for beverages such as fruit juices, nearwater drinks, iced tea, and energy drinks. 6

7 CONVINCING IN PRACTICAL OPERATION: WET ACF METHOD FROM KHS Eckes-Granini, leader of the European fruit juice market, relies on KHS ACF technology for its plants in Fallingbostel and Bröl Katharinental. The new ACF line installed at Fallingbostel is designed to process 24,000 PET bottles/hr and runs in three shifts. The line is equipped to handle a widest variety of bottling tasks. It processes 28- mm and 38-mm bottle mouths equally as well as carbonated products under filling pressure or non-carbonated products under pressureless conditions in addition to 1.5-liter plastic bottles. The PET bottle exteriors are first disinfected in a sectioned-off area before they arrive at the sterilizer/rinser located inside the clean room. The subsequent washing process is carried out by the computer-controlled KHS Innoclean triple-channel rinser designed to use three media: water, peracetic acid, and sterile air. With a peracetic acid concentration level of approximately 500 ppm, Eckes-Granini is able to operate with a fraction of the disinfectant concentration level normally required for wet sterilization processes. The rinsing zones and times and the disinfectant concentration levels can be set individually for each bottle shape and product and are available for push-button retrieval by the machine operator.the concept of a glass isolator with an additional sanitary safety room containing the rinser, filler, and capper is the basis for KHS wet method of modern clean room technology. Important for a successful production process is consistent handling of all the lines by employees. By conducting training courses, the experts from KHS contributed towards achieving maximum microbial safety in this case as well. At Eckes-Granini, aseptic cold filling is considered the filling method of the future for non-refillable PET bottles. 7

8 THE FIRST COMBINED REFILLABLE PEN/GLASS BOTTLING LINE FROM KHS The family-owned business beckers bester lives up to the company s guiding principle of focusing our attention on the consumer desire for health-conscious and fitness-oriented nutrition by preparing high-quality fruit juices and nectars with the help of gentle and ecologically friendly techniques. beckers bester is Germany s first fruit juice operation to bottle juice in refillable PEN and now sets the latest standards in hot filling of fruit juices in plastic bottles as well. Weighing only 63 grams, the new beckers bester 1-liter refillable PEN bottle is designed as an easy-to-handle, family-size bottle and is therefore extremely consumer-friendly. beckers bester invested very specifically in modern plant technology with its new KHS bottling equipment for its plant in Freinsheim. The new line is designed to process 1-liter non-refillable PEN bottles as well as 1-liter refill-able VdF glass bottles at a bottling capacity of 12,000 bottles/hr. A special highlight of the line is a double-end KHS Innoclean bottle washer equipped with Triple-i-Drive equipment that enables the bottle washer to process a widest variety of different bottle shapes, sizes, and materials while minimizing the time required for changeover. The heart of the bottling equipment is a KHS Innofill NRF long-tube filling system. The pressureless filling process for both glass and PEN bottles begins with a slow initial filling phase and then transitions into a low-turbulence filling process. A KHS Innoket Roland 16/4 labeler applies labels to the glass and PEN bottles. The principle of wet glue labeling is used to apply paper labels. Two labeling stations ensure that the body, shoulder, and back labels are exactly positioned thus enabling beckers bester, a pioneer in hot plastic bottle filling, to meet consumer demands perfectly and give its products a high-quality appearance at the point of sale. Our production is oriented entirely to customer demands. The ability to quickly change over from glass to PEN bottles and vice versa fits in very well with our plans. Thomas Schützke, Plant Manager at the beckers bester s Freinsheim plant 8

9 SWISS TRENDSETTER AGAIN OPTS FOR FLEXIBLE ACF TECHNOLOGY FROM KHS In the Swiss market, the Rivella brand is the clear Number Two among soft drinks after Coca-Cola and Rivella s Michel brand juices are the Number Three among brand name fruit juices. This great popularity implies a commitment to supply the consumer with only the very best quality at all times. For this reason, this Swiss company uses reliable plant equipment from KHS to bottle its carbonated soft drinks and non-carbonated fruit juices in a widest range of different shapes and sizes of plastic bottle. With a filling capacity of up to 30, liter PET bottles/hr, the new KHS ACF filling line at Rivella represents one of the most advanced and largest combined KHS systems in Central Europe that, in addition to 28- mm and 38-mm bottle mouths, processes carbonated products under filling pressure equally as well as non-carbonated products under pressureless conditions. As a pioneer in aseptic cold filling, Rivella was one of the first European beverage producers to utilize the advantages of this method for dairy products to achieve maximum microbial safety even for such sensitive products as whey drinks and fruit juices. Unlike conventional hot filling, higher product quality can be achieved through flash pasteurizing without the necessity of using preservatives. Only 20 percent of the original volume in comparison with the first generation of KHS ACF is located within the critical glass isolator zone of the third generation of modern ACF plant equipment now implemented at Rivella where class 100 clean room conditions prevail. With modern ACF plant engineering, KHS has once again provided an outstanding technology that prepares this Swiss company for further growth. There were several reasons, which spoke quite clearly in favor of KHS. On the one hand, the high flexibility of the ACF line that offers maximum system efficiency. On the other, it was extremely important for us that KHS provide the complete process engineering equipment as well as the filling equipment. Otto Weibel, Supply Chain Manager, Rivella 9

10 KHS ACF DRY STERILIZATION WRITES A SUCCESS STORY IN SERBIA By bottling fruit juices in 1.5-liter and 0.5-liter PET bottles, the Serbian Fruvita company s assortment of fruity beverages has been complete since The investment in KHS ACF system technology (dry sterilization) makes Fruvita one of the trailblazers in the implementation of modern ACF plant engineering worldwide. The top-priority goal is to offer the consumer natural products without preservatives, bottled under the strictest of microbial safety measures. Fruvita also benefits from the low space requirements of the barely 15-cubic-meter clean room volume versus that of the ACF wet process. The process sequences of the new KHS ACF technology designed for an output of 15, liter PET bottles/hr or 13, liter PET bottles/hr are carried out in an exceptionally compact mini isolator where class 100 clean room conditions prevail. The mini isolator comprised of three components, the sterilizer, the activator, and the filler-capper unit achieves maximum interior and exterior sterilization safety. The two-stage, open-jet filling valves of the pressureless, volumetric filling process that follows offer maximum flexibility. This also enables noncontact filling of beverages containing pulp or cereal as well as the more viscous non-carbonated beverages. Using electromagnetic inductive flowmetering ensures exceptionally exact fill volumes. All parameters relevant to the filler control are stored in so-called recipes for different products, bottle sizes and shapes, and filling capacities. When the recipe is changed, all the nec-essary information can be loaded into the filler control, and the sterilization and filling process reliably started. All in all, this means guaranteed process safety at the push of a button. We have achieved maximum flexibility with modern ACF dry sterilization plant equipment and are able to readily vary bottle sizes and shapes in the future. Goran Redzic, Fruvita s founder and CEO 10

11 FROM THE MACHINE TO THE SOLUTION FROM SERVICE TO PARTNERSHIP Economy and productivity over the entire life cycle KHS is backed by years of experience in planning, designing, and manufacturing filling and packing systems and knows what is important. Buffer zones are planned in advance, for instance, to ensure problem-free production in the long term. Our job does not end with commissioning, however. Our competence centers and service offices around the globe are the first point of contact for our customers even where care and validation of ACF systems by our microbiologists and process engineers is concerned. Good advice right from the start At KHS, service starts with your first contact: In the pre-sales area, our experienced employees analyze requests and check the feasibility down to the last detail. The result is a reliable, high-performance system offering a highly future-proof investment and high flexibility in the future. The new KHS Technology Center at the Bad Kreuznach plant contributes to this end where simulations of all filling and rinsing systems are available and where our staff of experienced experts provide laboratory support. Extensive laboratory tests can be carried out here on original customer products and bottles to meticulously determine the optimum filling system. In good hands worldwide: The KHS after-sale program With more than 60 service offices worldwide, KHS is available as a competent partner. With competent support ranging from project and system planning through commissioning up to and including assistance on aseptic issues. Remote support: The KHS ReDiS system Through fast and secure electronic remote diagnostics of the control system of your line, you can receive immediate assistance and answers to any questions you may have from our specialists. This shortens possible downtime, increases machine availability, and thereby improves the productivity of your lines. Maximum performance can be learned: KHS training All KHS systems have been designed and are able to achieve high availability and excellent efficiency, provided operating and maintenance personnel know how to handle the machines properly. For this purpose, the KHS Training Center offers intensive, hands-on training courses for your employees either at one of our locations or directly on site. 11

12 / OG FRUITFUL IDEAS BECOME SYSTEMS SUPPLIERS BECOME PARTNERS Be prepared for bottling fruit juice geared to market requirements with KHS. Talk to us about trends and requirements for future markets and your individual plans. We will be glad to give you sound advice. KHS AG Juchostraße 20 D Dortmund Fruit Juice Division Phone: +49 (671) Fax: +49 (671) juice@khs.com