Efficient Filling Technology

for Beer in Cans and Glass Bottles

Ludwig Clüsserath, Head of Development Filling and Process Technology / KHS
 Agenda

Filler for cans

Hygienic design as
development target
Innofill Can DVD

Filler for glass bottles

Innofill Glass DRS / DPG
Innofill Glass Micro DPG

Summary of filling technology

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 2

 Innofill Can DVD Can Filler –
Overview

Computer controlled can filler

Main application:
Beer, CSD, still and carbonated wine
beverages, champagne, sparkling wine
(prosecco), still water, juices cold and
hot filled

Can sizes 150 -1000ml

Max. output up to 132000 cph

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 3

 Innofill Can DVD Can Filler –
Development Targets (1/2)

Hygienic design to ensure product quality

Hygienic design to reduce cleaning and – 25%

disinfection efforts

Consequent hygienic sealing technology for the filling

valve including the centering bell

No permanent water lubrication of the filling valves

– 30%
Reduced CO2 consumption

– 40%
Reduced total oxygen pick-up

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 4

 Innofill Can DVD Can Filler –
Development Targets (2/2)

Linear and servo drive technology to reduce

– 20%
service and maintenance cost

Application of high-performance materials for + 50%

extended service intervals

– 25%
Fast product and format changeover

Elimination / reduction of grease and water lubrication

Suitable for Ultra-Clean-Filling of sensitive beverages

Optionally available UCF hygiene housing

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 5

 Innofill Can DVD Can Filler –
Machine Overview

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 Innofill Can DVD Can Filler –
Filler Carousel and Can Transfer Area

Computer controlled volumetric

filler

Volume measurement via

magnetic inductive flow meters
Filling volume deviation
s < 1 ml

Front table free can transfer

All-side accessible for cleaning and

disinfection

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 7

 Innofill Can DVD Can Filler –
Drive Concept / Can Transfer

Energy efficient drives located

protected inside stainless steel
columns

Separate servo drives for filler, can

transfer, infeed screw, infeed star
wheel and can seamer
No joint-shafts

Linear drives for cam position

No gear boxes or joint shafts

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 8

 Innofill Can DVD Can Filler –
Drive Concept / Can Transfer Area
Traditional drive system can filler and seamer

Motor for
height adjustment of lifting cam
Filler
Ball bearing
Gear box

Infeed star wheel Seamer

Gear box Infeed screw

Gear box with
drive for infeed
screw and infeed
conveyor

Joint shaft
Gear wheels
Main drive for filler and seamer
Gear box
Column for Joint shafts
height adjustment of lifting cam Front table

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 9

 Innofill Can DVD Can Filler –
Drive Concept / Can Transfer Area
New linear and servo drive system

Filler
Ball bearing

Servo drive filler

Infeed star wheel Seamer

Infeed screw

Servo drive
seamer
Servo drive for
Servo drive for
infeed star wheel
infeed screw and infeed conveyor
Column for height adjustment Linear drive for height
of lifting cam adjustment of lifting cam Frame

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 10

 Innofill Can DVD Can Filler –
Filling System in Hygienic Design

All filling relevant functions

integrated into one compact unit

Quick and easy disassembly

Media and pneumatic connections

are automatically connected when
the filling valve is mounted to the
machine

No pipes and cables in the

hygienic area

Automatic CIP cups

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 11
 Innofill Can DVD Can Filler –
Filling System in Hygienic Design

Technology up to now:

Movement of the centering

bell from the sterile into the
non-sterile area via a sliding
seal

Permanent water lubrication

above the cans

Water lubrication of the filling

valve centering bell lifting roller

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 13

 Innofill Can DVD Can Filler –
Filling System in Hygienic Design

Former version New version

Guiding of centering bell with Guiding of the centering bell
sliding seal with a PTFE bellow
Water lubrication of the sliding No water lubrication
seal above the open cans Integrated into the cleaning
Possibility of lubrication entering process
open cans Hygienically safe

Sliding seal PTFE bellow

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 14

 Innofill Can DVD Can Filler –
Filling System in Hygienic Design

Bellow and internal centering bell

guiding integrated into CIP
process

Tangentially positioned holes

distribute the CIP media through
the bellow

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 15

 Innofill Can DVD Can Filler –
Filling System in Hygienic Design

One centering bell for various can

end sizes

Universal seal for can end type

200 to 206

Universal seal

Can type 206

200

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 16

 Innofill Can DVD Can Filler –
Low-Pressure Can Flushing Process Can+ – Results*

Equal residual O2-Content in can Equal CO2-Consumption (800 gr/hl)

CO2 consumption Total oxygen pick-up
[gr/hl] [ppb]
1000

800 100

700
30%
560
50%

50

100

Filling valve up to now New DVD Filling valve Filling valve up to now New DVD Filling valve
* Beer in 500 ml can

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 19

 Innofill Can DVD Can Filler –
KHS Hygiene Housing with Reduced Room Volume

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 21

 Innofill Can DVD Can Filler –
KHS Hygiene Housing with Reduced Room Volume

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 22

 Innofill Canning Machines –
Certification for Energy Efficiency

Certification for energy efficient

systems engineering for electricity
and water

TÜV = Independent technical supervision organization

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 23

 Innofill Can DVD Can Filler –
Sales Success

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 24

 Innofill Glass Bottling Machines –
Overview

Computer controlled bottle filler

Main application:
Beer, CSD, carbonated water

Processible bottle heights

min. 130mm, max. 360mm

Max. output up to 70,000 bph

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 25

 Innofill Glass Bottling Machines –
Hygienic Framework for Bottle Transfer Module

Open designed framework instead

of classical front table to carry
bottle transfer parts and drives

Easy to clean

Self draining of liquids

Easy removal of shards

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 26

 Innofill Glass Bottling Machines –
Bottle Transfer Module

Modular design

Expandable to accommodate a
second or third capper

1st Capper
2nd Capper
3rd Capper

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 27

 Innofill Glass Bottling Machines –
Bottle Transfer Module – Format Part Quick Release

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 28

 Innofill Glass Bottling Machines –
„Innofill Glass“ is „Best in Class“

Certification for energy efficient

systems engineering for electricity
and water

TÜV = Independent technical supervision organization

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 29

 Innofill Glass Bottling Machines –
Filling System Comparison Innofill DPG / Innofill DRS

Innofill DPG Innofill DRS

Valve partially inside product vessel Valve flanged from outside
Fill level determination via length of Fill level determination via electrical probe
return gas tube (tube is easy to (automatic fill level adjustment optionally
change) available)
Tubular ring vessel

Computer controlled
Pneumatically operated
Return gas tube
Hygienic sealing technology

Swirl module

Electrical
probe

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 30

 Innofill Glass DRS Bottling Machine
Filling System

Compact design – all functions

contained in one unit

Easy to remove, fast and easy

maintenance

Ideal for targeted and efficient

exterior sanitizing

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 32

 Innofill Glass DRS Bottling Machine –
Filling System Cleaning – Automatic activated CIP Sleeves

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 33

 Innofill Glass Micro DPG Bottling Machine
Overview

Computer-controlled, short-tube
filling machine for low-oxygen
filling
With fill levels determined by
length of return gas tube
Application:
Beer, CSD, carbonated water,
wine and sparkling wine

Machines with 24 to 60 filling

stations

Output: 6,000 up to 25,000

bottles per hour

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 34

 Innofill Glass Micro DPG Bottling Machine –
For Low and Medium Filling Capacities

Compact design: Filler carousel,

machine front table and capper
form one unit

Free standing,
transparent machine cladding

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 35

 Innofill Glass Micro DPG Bottling Machine –
For Low and Medium Filling Capacities

Optional mono block with

Capper
mechanically controlled one-
Filler
channel rinser carousel
(available only for filler with
working ø 1440mm or ø 1800mm) Bottle rinser

Only one single servo drive for

rinser, filler, transfer stars and
capper
Tried-and-tested functional parts
from high-performance filling
technology utilized, such as lift
cylinders, filling valves, electrical
distributor, rotary product lead-
through, and capper Front table

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 36

 KHS Filling Technology
Summary

Consistent realization of hygienic Rapid change for product and

design container
Short cleaning and sterilization Low oxygen uptake with minimal
processes CO2 consumption

Automatic CIP cups for glass UCF technology available for

fillers and can fillers available sensitive beverages

Latest drive technology (torque, Easy to operate and easy to

servo, linear) maintain

Low energy and media Filling temperature up to 18°C

consumption

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 37

 Ludwig Clüsserath
Head of Development Filling and Process Technology
KHS GmbH

Planiger Straße 139-147

D-55543 Bad Kreuznach
Phone +49 (0)671 852-2501
Mobile +49 171 81 79 507
Telefax +49 (0)671 852-42501
E-Mail Ludwig.Cluesserath@khs.com

KHS
Competence in Solutions.
The information contained in this presentation is non-binding. Only the technical specification of our quotes are determinative with regard to design and scope of delivery. Subject to design modification.

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 38

 Notes

Sep-15 © KHS GmbH; Efficient Filling Technology for Beer 39