you care for the content. we care for the filling and packaging. As flexible as your products: Solutions for the markets of tomorrow While you take care of the further development of your variety of products, the experts from KHS provide you the ideal filling and packing processes. Regardless if you need competency in the beverage, food, or nonfood industries or whether your products are to be packed in bottles, jars, cans, pouches, or any other type of container. The company KHS With its origins dating back to 1868, KHS today is a manufacturer of filling and packing systems with one of the highest levels of performance and sales worldwide and with its approximately 3500 employees working in 13 production sites, KHS delivers complete systems and attractive individual solutions to 140 countries around the globe. With KHS as your partner, you can put your trust in a company that understands its customers and, backed by years of experience, offers the best prerequisites for securing futureproof success in your markets. Successful right down the line: KHS has the right solution to every filling and packing need. Whether individual machines or all-inclusive systems customer satisfaction is all that counts for KHS. KHS achieves more than you expect and with its extensive product portfolio also ensures maximum efficiency at your production plant. Plant planning and optimization Simulation to prevent errors and avoid additional costs Process engineering solutions Customized solutions from one source Cleaning/washing Resource-conserving cleaning/washing technology for maximum economy Filling Top quality, optimum performance Aseptic filling The latest standard of hygiene space-saving and future-proof Pasteurizing Low energy and water consumption coupled with maximum process reliability Inspection KHS is one of the leading suppliers of quality control systems Labeling Maximum flexibility and precision for the changing needs of brands, today and in the future Container, pack, and pallet conveying For smooth intralogistics Packaging Modular design ensures application flexibility Palletizing A worthwhile investment taking life cycle costs into account All this, in addition to a service package that is available to you for the entire life of your machines guaranteeing disruption-free production processes. From the planning to the aftersale phase, with KHS you have a reliable and competent partner at your side. 2
ONE INNOVATIVE SOLUTION AFTER THE OTHER: AT KHS, THE EMPHASIS IS ON CUSTOMER BENEFIT Ideas promising real added value from KHS The long list of innovations is based above all on the pioneering spirit of KHS employees who contribute significantly to our success in the market. Adapted versions of many designs engineered for the high-performance-oriented beverage industry can be found in the food and nonfood industries because they also make a decisive contribution towards increasing efficiency and effectiveness of these sectors. A rotary filler for instance, that helps the dishwashing liquid industry achieve top performance, or absolutely no-drip filling valves for liquid soap, labeling systems designed especially for cans, or ingenious palletizing solutions for sugar. The focus at KHS is always on maximum customer benefit at a suitable price/performance ratio. The motto in the food and nonfood sectors is To see through the eyes of the customer in order to perceive consumer demands and meet these demands accordingly. Modularly designed machines to shorten line conversion and improve flexibility Maximum reliability of trouble-free production processes Modern, resource-conserving, and operating-cost-minimizing technologies Easy to operate machines with little personnel dependency Systems tailored to your capacity requirements Simple conversion of all KHS systems such as the KHS Innoket ROLAND 4
CUTTING-EDGE INSPECTION TECHNOLOGY FOR YOUR PRODUCTS: QUALITY ASSURANCE EARNS CUSTOMER TRUST In addition to the significance of the packaging, quality remains one of the decisive criteria for buying or refusing to buy a product. If a product does not taste good or if the contents are damaged or spoiled, even a very attractive packaging will no longer be able to limit the damage to reputation in the eyes of the customer. Ultra-modern inspection technology is therefore a necessity today for quality assurance in order to maintain the expected high product quality and to earn customer loyalty. KHS Metec offers an extensive range of inspection machines that meet the demands of perfect quality assurance by implementing leading-edge technologies and a wide variety of inspection capabilities that fulfill virtually all customer requirements. KHS Metec inspection machines operate efficiently and reliably when it comes to identifying objects, checking production codes and labels, checking fill levels or detecting leaky containers. The capacities of these machines are easily customized to customer requirements. They additionally offer convincing ideas for economical solutions that provide your production process decisive advantages. Such as the total quality label inspection concept, for example: Four CCD cameras take a picture after each 90 turn of the product to be inspected. All images are brought together to form a 360 -picture and enabling visible inspection in the 3D module. Individual process sequences are grouped together by combining label and laser code inspections. Added to this is the machine s exceptional ease of operation. Simple teach-in of changed or new products with minimum operator effort is yet another advantage. Inspection technology could not be implemented more effectively. Whether inspecting tea bags or checking containers for the milk or meat processing industries or the producing chocolates or implementation in the pharmaceutical industry or household chemical sector KHS supports them all in every respect. KHS Metec offers reliable solutions with clear customer benefits: High machine availability and reliability (e.g., no machine downtime) Optimum product quality through guaranteed clean shapes Immediate rejection of defective products Reduction of complaint rates Customer-specific customization easily possible Minimization of production costs; lower labor costs Extensive internal and external data management (e.g., statistics, PDA connection) Direct link to automation Stainless steel design (IP65) for full suitability for industrial applications 5
FUTURE TECHNOLOGIES BASED ON TRADITION: INTELLIGENT FILLING SYSTEMS FOR MAXIMUM PRODUCTIVITY The trend towards aseptic filling in the food sector continues growth rates of up to 8 % are expected in the coming years. KHS has been setting the standard in aseptics for years and has profited from its continuous efforts to make a good thing even better. ACF dry sterilization, for instance. This is a patented system that completely eliminates the need for water for the sterilization process thus making it a resource-conserving and environmentally sound system. ACF dry sterilization, which has become well established especially in the milk processing industry, takes up only a small amount of space another cost-cutting aspect. No wonder that many dairies such as Poland s leading dairy, Konskie, have already decided in favor of exceedingly efficient ACF filling lines from KHS. In the food sector, KHS also offers filling solutions for highly viscose substances and additionally shows its expertise in the nonfood branch of industry. It was thus possible for one of the world s leading producers of dish liquids to increase its production output by implementing a KHS rotary filler instead of the previously installed in-line model. Moreover, an absolute no-drip filling valve was used that guarantees 100 % performance without smearing bottles and dripping product on the machine. These arguments were decisive in the company s decision in favor of a filling system from KHS. Technical optimization of its filling systems taking the latest in economical and technical aspects into consideration is the primary goal at KHS. For this reason, customers from the food and nonfood sectors are now profiting and will continue to profit from the many useful details and experience gained from classic beverage filling where KHS has always proven its pioneering spirit. Design characteristics of KHS machines: Modular design Central control Ease of operation Only a few wear parts Low maintenance Great flexibility in the choice of container types Exact filling Simple sanitizing Economical and resource-conserving Other competencies: Filling of vinegar, oil, viscous substances such as jam and mayonnaise as well as lumpy products. Also liquid fertilizers and motor oils in addition to cosmetic products. 6
A system technology that makes us fit for further brand expansion. Hieroniem Michalowski, Deputy Chairman of the Konskie Dairy, Poland Filling technology with a future: ACF dry sterilization An all-round solution: the revolutionary filling system for dish liquids
KHS LABELING TECHNOLOGY KEEPS THE PROMISES YOUR PRODUCT QUALITY MAKES The need for a wide variety of products in the food and nonfood sectors continues to grow while the gap between the discount and classic retail segments continues to widen. Under these conditions, it is becoming increasingly difficult to diversify and position brand products. This is done primarily through an attractive appearance, which is extremely important for consumers and is the main criterion for a decision to buy, even more than the brand name. KHS has developed an especially efficient approach to solutions in the field of labeling technology. With our modular design concept, we offer you maximum flexibility in the design of your products enabling you to achieve a first rate product presentation at the point of sale. The old-established Göbber company, for example, had L-shaped labels created that were to be applied completely to jars containing its premium product, Göbber 70 Frucht. KHS offered a solution with numerous options for further label styles to give the product an optimum appearance and stimulate retail sales. Flexible labeling technology from KHS is also highly regarded in the nonfood sector as well. It was thus the gentle product handling technology that was the primary factor in washing detergent producer Henkel s decision to purchase machines from KHS in addition to exact application of labels to its Spee brand of liquid detergent. This gentle handling prevents damage to the visual appearance of sensitive packaging materials, which could negatively affect sales, and at the same time ensures a 100 % production process. Another advantage is the low cost of developing new labeling solutions. Whether special labels, Styrofoam cups, or labels with a height to length ratio of 1:10, KHS offers well thought-out solutions in the entry and high performance range. Design characteristics of KHS machines: Modular design offers the flexibility needed to meet changing consumer demands Tool-less format part and automatic reel changing facilities ensure high machine availability and reduce downtime KHS Innocoll glue program is the ideal enhancement for all labeling machines Ease of operation and little effort for operating personnel Other competencies: Adhesive-pressure, tamper-evident, and special labels for cups, canisters, and other typical food and nonfood containers 8
The new labelers comply with the stringent Henkel quality specifications in every respect. Martin Petzoldt, Project Manager at Henkel This impression sticks. Optimum labeling captures edges in the market A premium labeling solution for a premium product: Göbber jams 9
OPTIMUM PROTECTION AND PERFECT APPEARANCE RIGHT DOWN THE LINE: KHS PACKING TECHNOLOGY ACCOMPLISHES MORE It is mainly a matter of ensuring a sales-promoting, visually attractive appearance in addition to optimum product protection during the entire logistics process up to an including placement at the point of sale. Because a perfect appearance is vital for survival, especially in the food sector that offers a vast assortment of products. Globally active HJ Heinz, for example, decided in favor of a shrink packing solution for its top selling baked beans and spaghetti products; a solution that is normally one of the classic packing modules in the beverage industry. The benefits: absolutely stable and attractive packaging to which a special KHS insert system is able to insert small extra gifts as customer incentives. KHS thus offers users capabilities for coping with the increasing significance of promotional items by including small goodies to promote sales. The handle applicator is yet another practical opportunity to make products even more convenient to carry for consumers. It cuts costs and enables users to react flexibly to consumer demands. The packing machines themselves ranging from the tray packer and pad shrink packer to the wrap-around packer and the wrap-around shrink packer prove that high output and high efficiency can harmonize perfectly. Thanks to the modular design and production sequences logically linked in series with virtually 100 % machine availability and little personnel effort. This all ensures maximum logistics efficiency through optimum utilization of conveying and storage facilities. KHS has also demonstrated its proficiency in the nonfood sector by developing a shrink pack system for KimberlyClark, for instance, to pack fragile cardboard boxes containing cosmetic tissues. A shrink packer was also combined with a tray packer for Johnson Wax Europe to pack spray cans for safe and convenient transport. Design characteristics of KHS machines: Modular design offers flexibility for changing consumer demands Added value through insert systems and handle applicators Tool-less format part and automatic reel changing facilities ensure high machine availability and reduce downtime Increased efficiency by automatically adapting to the required output range Ease of operation and little effort for operating personnel Other competencies: All standard container shapes 10
We have been relying on KHS Innopack Kisters packing machines since the early 1980s and are extremely satisfied with the machine equipment. Simon Partridge, Project Manager at Heinz Optimally packed for perfect placement at the point of sale Safely and conveniently packed: spray cans 11
ENGINEERING FEAT: EXCELLING WITH INTELLIGENT PALLETIZERS The increasing variety of products in the food industry means considerably more time and effort involved in logistics. This not only prerequisites supplying the desired products to the trade in perfect condition within a minimum amount of time but also requires an intelligent, perfectly coordinated palletizing system. A system that must be capable of changing over to various types of goods and properties and offer high performance for time-saving and cost-cutting palletizing coupled with optimum layer formations. This is the only way to achieve maximum conveying and storing safety and reliable presentation of your products at the point of sale a decisive competitive edge. The palletizer should additionally have a small footprint, be easy to operate and run reliably all requirements that KHS palletizing systems fulfill perfectly. In the food sector, companies such as Danone and Pfeifer & Langen have long since placed their trust in the engineering feats from KHS. Whether palletizing yogurt or packages of sugar perfect and fast palletizing with intelligent components such as single-intelligence controls, easy reprogramming, maximum positioning and control accuracy through servo drives and high machine availability contribute significantly towards long-term cost reduction. An important advantage in the food sector, which is marked by constant pricing pressure. The performance of KHS palletizing technology is compelling in the nonfood industry as well. KHS developed and delivered a special palletizer to a wood processing company that was adapted to the typical requirements of the trade. The ruggedness of the KHS machinery was a decisive criterion since wood shavings and ambient conditions such as sawdust present no problems thanks to intelligent approaches to the solution. KHS was able to fully exploit its experience in the beverage trade where machines are likewise operated under a widest possible variety of climatic and ambient conditions. Design characteristics of KHS machines: PC-based control of the entire process Fast, flexible changeover in order to palletize virtually all types of product Gentle processing of even the most sensitive of products Exact positioning by servo drives Top output of up to 120,000 items/ hour Up to 570 kg load bearing capacity for articulated robot solutions Rugged design ensures high machine availability Small footprint Conversion from low to high speed Other competencies: Virtually all types of product and pack; also pick-and-place equipment 12
The greatly expanded functionality in conjunction with the advantages of the servo technology and PC-based robot control meets maximum demands. Wolfgang Wirtz, Plant Manager for Assortment/Packaging, Pfeifer & Langen KG All made of sugar: KHS palletizing technology sweetens sales Relying entirely on wood with palletizers from KHS 13
THE FUTURE IN A BAG: KHS COMPLETE SOLUTIONS FOR FLEXIBLE PACKAGING Form/fill/seal pouching machines from KHS State of the art solutions: KHS fills fin-seal bags The versatile, practical, and cost-efficient pouch has long since become established as a tried and tested style of packaging for products in the food and nonfood sectors. Added to this are optimum retail presentation capabilities that make the pouch increasingly attractive for marketing. For this purpose, KHS has developed a new generation of fin-seal and standup pouching machines that require a shortest possible amount of changeover time and offer maximum flexibility. More and more frequently, two or more machines need to be changed over during each shift in the past, a time- and costconsuming process. In addition, the entirely new design open toward the floor enables quick and thorough removal of product residue thus eliminating yet another problem. As one of the leaders of the market worldwide, it is no wonder that KHS has installed nearly 4,000 pouching machines to date. Enhancements to the line: KHS cartoning machines KHS also offers the matching cartoning machines and palletizing solutions that boost the capabilities of the entire line. Whether pans, tubes, cans, trays, cereal bars, or soap dispensers the cartoning machines from KHS are able to quickly, efficiently, and reliably pack these products. IMC/sm series machines process up to 200 cartons per minute in intermittent mode and CMC/sm series machines pack up to 600 cartons per minute in continuous operation mode. These stainless steel machines are well suited for use in the food and pharmaceutical branches of industry. We also offer various product transfer system models adapted to your products. Talk to us about your individual requirements. 14
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. Planning begins by comprehensively simulating all production flows to ensure lasting disruption-free production. 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 offering complete after-sale services ranging from servicing, maintenance, and repairs through upgrades, expansion, and conversion up to and including training and remote diagnostics (ReDiS). In good hands worldwide: The KHS after-sale program KHS is available as a partner everywhere in the world offering complete support ranging from plant and project planning to commissioning and more. Maximum performance is learnable: KHS training courses All KHS systems are designed for high machine availability and outstanding efficiency. Prerequisite, however, is that operating and maintenance personnel know how to handle the machines properly. The human being is and will continue to be a decisive factor in the efficiency of complex systems. The KHS Training Center offers intensive, practice-oriented training courses for your employees either at our facilities or directly at your site. Remote support: The KHS ReDiS system Through fast and secure electronic remote access to the control system of your line, you can get immediate assistance and answers to any questions you may have from the competent specialists at KHS. This shortens downtime, increases machine availability, and thus improves the productivity of your line. When a service call is received from a customer in Portugal in the morning, it is naturally part of our job to be there in the afternoon to get the job done. (Leif Bösken, mechatronic technician, Labeler Field Assembly) 15
30 1992-01-181/2 0906 OG SYSTEMS COME FROM CONSUMER TRENDS SUPPLIERS BECOME PARTNERS Prepared for tomorrow s markets with KHS Talk to us about your requirements and individual plans for future markets. We will be glad to give you sound advice. KHS AG Juchostrasse 20 D-44143 Dortmund, Germany Phone: +49 (231) 569-1668 Fax: +49 (231) 569-1226 E-mail: foodandnonfood@khs.com www.khs.com