Current conversions:  electrical equipmentand drive on a pasteurizer

Special challenges

The machine is on the top floor of the brewery;this means that a crane had to remove 21 metric tons of old parts and then bring in 26 tons of new parts. All this had to take place within a fixed timeframe of three weeks.

Improvements made:

  • The pasteurized is now up to date and can workcompletely reliably for the next 15 years.
  • The PU control enables gentle pasteurization of the individual products.
  • The machine is now connected to KHS through ReDiS*  (ISDN or VPN), thus enabling direct online support from KHS Service personnel in the event of any faults.

* Remote Diagnostic Service

The conditions governing economic success in an industrial environment are not becoming any easier. Global competition and changes in customer and consumer demand regarding cost-effective quality products are presenting companies with ever new challenges. The maxim in all cases is to opt for a flexible and durable system which is also economical and ecologically sustainable.

This also applies to upgrades, with which existing customers can bring their older, robust KHS filling lines into line with the state of the art so that they are better placed on the market. The most recent examples of such cooperative solutions in the decision to modernize ­rather than make a new investment are Karlsberg Brewery in Homburg in Germany’s Saarland and the big Japanese beverage concern Asahi, both long-standing customers of KHS.

At Karlsberg the walking beam system on the KHS pasteurizer from 1991 had gradually become susceptible to faults. After much consultation with the KHS service team the brewery decided neither to repair its existing system nor invest in an extensive replacement system. Instead, Karlsberg opted to convert its pasteurizer from the walking beam system to modern belt systems with a stainless steel belt and new PU (pasteurization unit) control. At the same time all of the electrical equipment was replaced as Siemens had discontinued the components installed in the old system (S5 control unit).

Umbau des Pasteurs: In drei Wochen realisiert.
Pasteurizer converted in just three weeks.

Contact project Carlsberg

Jürgen Thielen
head of Service North Europe Department
KHS GmbH, Dortmund, Germany

Phone: +49 231 569-1851

Contact project Asahi

Andreas Bentin
Project Responsible Bottles & Shapes/Retrofits
KHS Corpoplast GmbH, Hamburg, Germany

Phone: +49 40 67907-227


Efficient upgrade I

The Karlsberg example

The company: founded in 1878 and based in Homburg in the German federal state of the Saarland, the brewery is both traditional and innovative. Its well-known brands, some established for decades, include Karlsberg UrPils, Feingold, a wheat beer and a natural shandy and have won a number of awards. The company also markets various mixed beer beverages and non-alcoholic beers, such as Gründel’s classic, Gründel’s fresh and the in-beverage MiXery (beer + cola + X), plus fruit juices and mineral water through Karlsberg Holding. Karlsberg Brewery had two glass and one canning line and a kegging system from KHS.

Current conversions: compressed air savings

Special challenges

Asahi only granted KHS Service five days of machine downtime for the necessary conversions.

Improvements made:

The new AirbackPlus system (available from InnoPET Blomax III and higher) considerably reduces the consumption of the air generated by the energy-intensive highpressure compressor: measurements after conversion recorded a saving of 35%.


Efficient upgrade II

The Asahi example

The company: the origins of the Japanese concern date back to the year 1889. After several mergers, restructures and consolidations Asahi is now one of the big inter­national beverage producers with a significant market presence and licensed production in Europe, too ­(England and the Czech Republic). The company is listed on the ­Nikkei 225 and headquartered in Tokyo in a skyscraper ­designed by Philippe Starck to resemble a glass of beer with a head of foam. The product range includes many brand beers (mostly lager) and also Japanese Nikka brand whiskies, traditional Japanese shochu spirits, non-alcoholic beverages and wine.

“The entire conversion process was extremely harmonious, running without any hitches or lengthy delays,” smiles Hans-Jürgen Peter. It may be no surprise that the head of maintenance at Karlsberg is so full of praise but it wasn't given as a matter of course; almost 50 metric tons of material (equivalent to the weight of 30 VW Golfs) and the machine itself had to be moved by crane during dismantling and installation – plus the line in question was on the top floor!

Everything came perfectly together on this project: the planning, on-time delivery of all conversion groups, the experience and expertise of the KHS team and the unusual amount of support provided by Karlsberg personnel. A total of 50 engineers overhauled the line at the same time. The result of three weeks of cooperation was duly impressive: just four days after line commissioning Karlsberg signed the acceptance report with no reservations whatsoever. Says Peter, “My great thanks goes to all those involved in helping this unusual project – both for us and KHS – to run so smoothly.”

Lucrative conversion to save energy at Asahi completed in just five days

he conversions at the Asahi sites of Akashi and Fuji in Japan were also reliably performed – despite the schedule being much shorter with just five days of machine downtime. KHS had presented the experts at Asahi with very detailed technical documents in advance so that they could perfectly study the planned conversion of the system to AirbackPlus  (a high-pressure recycling system which saves compressed air) and better assess any possible risks. A number of phone conferences and on-site meetings then took place, during which KHS was able to coordinate the exact procedure with the customer.

The company is now very pleased with its new blow air controller which uses up to 35% less compressed air and thus energy. Satisfied KHS key account Asahi lets actions speak louder than words – and at present has no less than seven KHS stretch blow molders in operation within the company.