Rafet Doğanay, Mitinhaber, Leiter Marketing und Vertrieb Doğanay Gıda.

Doganay Gida, Türkei

In consumer focus: glass in PET thanks to Plasmax technology

Doğanay Gıda, one of the biggest producers of fruit and vegetable beverages in Turkey, is the first company in the world to use unparalleled KHS Plasmax technology (glass in PET) as a unique selling proposition advertising its quality Limonata product.

With Plasmax technology the insides of PET bottles are barrier coated with a layer of pure glass,  which provides even the most sensitive of beverages with longer protection against loss of quality. The wafer-thin layer of glass prevents the exchange of carbon dioxide, oxygen and flavorings between the product, packaging and the environment.

In order to convince Turkish consumers of this new idea the family business, headed by brothers Remzi Doğanay (CEO, production manager) and Rafet Doğanay (co-owner, head of sales and marketing), has launched a professional TV campaign in three parts. An initial TV commercial first showed how difficult it is for consumers to decide between the glass and the PET bottle. The second broadcast promised that it is no longer necessary to choose between the two now that what’s known as the glass/PET bottle (Turkish “CamPET”) is available.  Only in the third part of the trilogy did the marketing strategists reveal that Doğanay Gıda’s Limonata is available in the sensational CamPET bottle and that this is 100% recyclable.

Incidentally, the company also placed film clips on YouTube (www.youtube.com – keyword: CamPET Doğanay) and set up glass/PET pages on Twitter and Facebook and in the Internet (www.campetsise.com). Within a few weeks the company had already chalked up more than 100,000 followers. Says Rafet Doğanay, “The response to our campaign was and is outstanding. Although we expected a lot of interest, we couldn’t possibly imagine just how fascinated consumers would be by the glass/PET idea.”

All this fits in perfectly with the company’s high demand for quality. This is also evident in the fact that Doğanay Gıda, ­founded in 1997, just recently commissioned no less than three aseptic lines from KHS, which with the new Plasmax barrier technology will give products a much longer shelf life in the future. Each of the three lines processes up to 36,000 0.25 or 1-liter bottles per hour. “The lines have an efficiency of over 90% and we were able to put them into operation within a very short time indeed,” Remzi Doğanay is full of praise. “What we particularly like about them is that the third line utilizes the new generation of KHS aseptic rotary machine technology. As we see it, this actively safeguards our future.

For Doğanay Gıda has concrete plans. In the near future the company in the major South Turkish city of Adana wishes to produce iced tea and add grape, pomegranate, apple, and mandarin juice to its juice portfolio. Other new products are to follow. For the juices alone, which consist of 100% freshly pressed fruit and keep for nine months without refrigeration in aseptically filled glass PET bottles thanks to a special production method, the company is reckoning on a further clear increase in sales in 2015.  To sum up, Remzi Doğanay states, “In our view the CamPET bottle and our KHS aseptic lines play a major role in this proposed story of success.”

Cervecería Austral, die südlichste Brauerei der Welt – seit 1896 in Punta Arenas, Patagonien, Chile.

Cervecería Austral, Chile

In Magellan’s footsteps

In the southernmost brewery in the world, in Punta Arenas in Chile opposite the Straits of Magellan and close to the Antarctic, now stands the first KHS microfiller for glass bottles in South America. The Innofill Glass Micro DPG bottle filler was ordered by Cervecería Austral, the oldest brewery in Chile still active and the oldest manufacturing company in Punta Arenas. The premium beer supplier has thus opted for state-of-the-art filling equipment based on high-performance KHS technology (up to 75,000 bottles per hour) which KHS has ­precisely­ adapted to meet the requirements of the medium-sized enterprise.

Cervecería Austral now produces up to 12,000 bottles an hour on the line which includes a rinser, filler, two cappers, and machine infeed and discharge conveyors.

The brewery processes smaller beer bottles with crown corks and large bottles with plastic screw caps. The project was extremely complex and excellently implemented by the local international KHS project team.

The experts not only had to install the specially engineered machine in a production shop just three meters high; Punta Arenas is also a very hard location to access. “It was thus a great achievement that the undertaking was concluded in a very short time indeed,” state Eric Walter Roeschmann, general manager, and Armando Jordán ­Astaburuaga, technical manager at Cervecería Austral, unanimous in their praise.

In their search for a business partner Austral’s top priorities were extremely reliable technology, good service and fast availability of spare parts. As the microfiller ­largely consists of parts which are identical to those of its bigger cousins, KHS’ high-performance machines, stockpiling universal spare parts is much easier, thus ensuring fast/even faster availability among the various plants in the group – a benefit which had the company convinced right from the start. Reliable production is a very important factor in Punta Arenas as the production site is over three hours by plane from the Chilean capital of Santiago.

The managers were convinced by the many benefits of the KHS system during the course of various presentations and machine viewings in both Chile and Germany. The main arguments which proved most persuasive to Cervecería Austral were the low oxygen pickup and low consumption of CO2. So please note: even in the southernmost brewery in the world, reliability and quality count for everything!

Auf der Erfolgsleiter über der Anlage (von links nach rechts): Nicolas Deus, Geschäftsführer Hijos de Rivera; Alejandro Alonso, Technischer Leiter Hijos de Rivera; Miguel Pastor Vivancos, Managing Director Klöckner Holstein Seitz, S.A. (KHS Spanien); Manuel Fernandez, Bereichsleiter Verpackung/Abfüllung Hijos de Rivera; Carmen Germann, Head of Sales South Europe Department Südeuropa KHS; Raul Mendez, Einkaufsleiter Hijos de Rivera.

Hijos de Rivera, Spanien

A star in Galicia

Traditional family business Hijos de ­Rivera­­ (star of Galicia) recently installed two packaging and palletizing sections for its existing glass and canning lines. The com­pany subsequently decided to procure a complete new KHS glass line for non-returnable containers which outputs 50,000 bottles per hour, which KHS delivered this year.

What’s special about both of these projects is that the machinery was installed on three different levels. These are operated with the help of lifts and driverless conveyor systems. All told, this setup gives the brewery great efficiency and extraordinary flexibility.

The one-way line supplied by KHS ensures top quality values throughout the entire filling process.

With 109 years under its belt, the traditional business is currently experiencing a real upswing, already trumping the average brewery sales figures in Spain.

Crown Beverages, Uganda

Crown Beverages, Uganda

First in East Africa

The first KHS PET line in East Africa has been up and running since the middle of November last year at Crown Beverages Limited (CBL) in Kampala. The only Pepsi bottler in Uganda has worked with KHS for over 15 years. The new PET line has a capacity of 24,000 0.5-liter bottles per hour and at CBL it also processes 0.33-liter bottles (various containers holding up to 2.0 liters are feasible).

The line output is 95% maximum and CBL also saves energy and costs for cooling, among other things, compared to its previous system from a competitor.

As Crown Beverages wanted to commission the line at very short notice and launch its products to market in time for Christmas, KHS promptly flew the entire system out to Uganda on an ­Antonov and Boeing 747 and installed the line in record time. The blow molder features the new ClearLine design and the line also includes an Innoket 360S labeler and a pad shrink packer.

Crown Beverages has been in business in Uganda since 1950. Initially founded as Lake Victoria Bottling Company, in the meantime the company exports its products to several neighboring countries.  CBL’s premium CSD  brands include Pepsi, Mirinda, Mountain Dew, 7 Up, and Evervess.