Case Study

KHS Maschinenund Anlagenbau AG

Asia Pacific
Breweries Ltd.

Weltmesse Nr.1 fr Getrnkeund Liquid Food Technologie

Messe Mnchen GmbH

Messegelnde
Mnchen
81823 Germany

New Munich Trade Fair Centre

12.-17.9.2005

World Fair No.1 for Beverage

and Liquid Food Technology

Phone (+49 89) 949 11318

Fax (+49 89) 949 11319
info@drinktec.de
www.drinktec.de

Technical Innovation Leadership through advanced KHS Plant

Engineering for Multiple Shift Production at Asia Pacific Breweries
Categories

1. Plant and machinery for beer production, malting and silo technology
2. Cleaning, filling and sealing machines for bottles, cans, soft packs, kegs,
casks and other containers
3. Inspection and sorting machines, monitoring equipment
4. Etikettier-, Ausstattungs-, Druck- und Signiermaschinen
5. Unpacking & packing machines / multiple packing machines
6. Palletising, depalletising and discharging equipment, conveyors and
intermediate storage, order picking equipment
7. Cleaning, disinfection and sterilisation systems, dust removal systems
8. Computing, IS and IT solutions, documentation

Market Sector

Breweries

Short Description

Two complete filling lines for one-way and returnable glass bottles respectively.

Delivery and installation of plant and equipment without interrupting production.

Automatic control of the two lines, enabling a specific line interchange.

Three-shift operation output at the one-way-bottle line und returnable-bottle-line

amounts to 24.000 0,33-l-bottles/h and 18.000 0,64-l-bottles/h respectively.

Task

Delivery and implementation of plant and equipment for one KHS one-way bottle
filling line and a KHS returnable bottle filling line for the APB-plant in Singapore
without disrupting production at the working lines.

Initial

The new investment for the APB facility in Singapore required for two new KHS lines,
one for returnable glass and one for one-way glass bottles to replace two existing
lines. A maximum of two weeks production interruption for each line was allowed.
This necessitated several installation phases, which were all based on the following
scheme: first step - removal of parts of the existing line equipment and integration of
new machine equipment, without actually replacing any units. Second step: thorough
testing of the new machine equipment, followed by the final step involving integration
into the line and removal of old electronic components. The staged introduction of
new components was scheduled according to plan based on the available space.
Things worked out well: production was not interrupted once during the configuration
and testing phases.

Implementation

Asia Pacific Breweries Ltd., one of the largest South East Asian breweries, saw the
need to accommodate rising demand for their brands by expanding their production
facilities in Singapore. They asked KHS Maschinen- und Anlagenbau AG to build
and assembly two new filling lines.
Today, both one-way glass and returnable glass bottle lines operate in three shifts
with a capacity of 24,000 0.33-liter glass bottles per hour and 18,000 0.64-liter glass
bottles per hour respectively. Both lines are designed for filling the desired range of
APB products in a wide range of container types. Both lines are additionally

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characterized by high flexibility, short changeover times, and minimum operator
dependence. The one-way glass and returnable bottle lines can also operate
together whenever necessary and possible. The flexibility of the lines also link with
the existing canning line such that cans can be packed with a similar configuration
using the new innovative equipment from the bottle lines.
One of the two Innopal AS new glass depalletizers installed directly adjacent to each
other within the lines deals with the returnable glass bottle line. If the quantity of
returnable glass bottles is insufficient, this new glass depalletizer automatically
springs into action. The second new glass depalletizer continuously supplies the
one-way glass bottle line with new glass bottles. Both depalletizers achieve full
nominal line capacity. If necessary, the Innopal AS provided for the returnable glass
bottle line can thus also be used for the one-way glass bottle line, and vice versa.
Within the returnable glass bottle line, Innopal RS3 column-type robots handle the
task of palletizing and depalletizing crates. The Innopal RS3 is a multiple-station
palletizing robot with a working radius of 180. This means versatility and flexibility
within a minimum amount of space. A special advantage of the Innopal RS3: the
palletizing and depalletizing processes only require a single clamping head each.
The heads can easily be adjusted when the line is changed over to a different
container type. Here too, changeover times are confined to a minimum.
Two Innopack RS column-type robots take care of crating and decrating. The
packing heads of the crater as well as the decrater are changed fully automatically
when changing the type of crates and/or bottles. Both column-type robots have
been designed to place the current packing head and correction frame in the space
provided for this purpose in a magazine, and then to attach the new components.
The changeover process takes only a few minutes. For the crater, the lane control of
the feed table is also replaced. A process that also takes only a few minutes to
complete.
The KHS modular dry area concept is highly intelligent solution as control is handled
by a single PC-based computer. Unlike conventional control concepts, this solution
uses a single intelligence approach for transferring information to all other system
components via modern bus equipment thus ruling out all interface problems.
Possible trouble spots can be pinpointed immediately. Direct, real-time communication links and computer-controlled sequences of motion guarantee high cycle times
and maximum precision when scanning travel profiles entirely without sensor
components. Another advantage of the modular KHS design: horizontal and vertical
movements are generated exclusively by cog belts. This means maintenance-free
operation in addition to lower noise levels. Servomotors shorten cycle times and
ensure high performance coupled with exact adherence to the so very important
positioning accuracy. Within the returnable glass bottle line, decrated glass bottles
are sent to the Innoclean DM double-end bottle washer. The crates are sent to the
Innoclean KW crate washer and subsequently either to the crater or to a crate
magazine integrated in the system, which ensures continuous flow within the line.
Compared with the single-end method, the double-end bottle washing technique
offers the advantage of multiple caustic baths (three at APB Singapore) and
consistent separation of the dirty bottle infeed and clean bottle discharge. Moreover,
graduated temperatures and concentrate levels can be adapted to the particular
style of bottle. For APB this graduation is significant, not only because of the wide
range of bottle styles that are used, but also because at times of low returnable glass
bottle availability complete batches may be filled in new glass bottles. Advanced
KHS cleaning technology adapts the cleaning program individually to new glass
bottles. The bottle washer is additionally equipped with Triple-i-Drive technology.
This Triple-i-Drive technology minimizes the time required for changeover to a wide
range of different bottle styles. Once the last bottle has entered the machine, the
infeed can be completely disengaged from the drive. Changeover work can begin
while the bottle washer is running. The same is true for changing over the discharge
to new container shapes.
The filling system in operation for returnable glass bottles is a computer-controlled
Innofill DRS-ZMS pneumatic pressurized filling system that operates with filling level
probes. The filling process is preceded by double pre-evacuation and double CO2
purging. Exact filling levels are determined by filling level probes. The advantages of
this filling system are short product and bottle changeover, high machine availability

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based on central filling level adjustment, non-speed- and non-standstill-dependent
processing sequences, adaptation of the filler output to the output of the particular
line, and the extremely low-oxygen filling process. The microbiological filler front
table ensures maximum microbiological hygiene in the vicinity of the filler.
Following the filling and capping process, processing continues in the single-deck
Innopas PI pasteurizer. The pasteurization process is constantly monitored and
optimized by an integrated PU control system. A computer, linked with the pasteurization process indicates actual product temperatures and infeed pasteurization units
based on the treatment time and continuously measured spray temperatures in each
of the zones. Any necessary control actions can be carried out quickly based on the
information gathered.
Regarding the labeling equipment, the returnable glass bottle line uses an Innoket
KL 2080. In this specific installation, the Innoket 2080 is equipped with three labeling
stations. The labeling stations can apply the following label types as required:
shoulder, body, neck, and back labels and aluminum foil over crown corks. Ease of
operation, low maintenance, and assurance of optimum hygienic conditions are the
key features of the Innoket KL 2080 labeler. This generation of labelers is equipped
with automatic vertical head adjustment so that no manual work is required for
possible bottle style changeovers. The labeling stations operate according to the
principle of rotation, using the electronic VarioDrive bottle turret control.
After the labeling process, the returnable glass bottles are usually sent to the crater
and palletizer. It is also possible, however, to feed the bottles to the new KHS oneway glass bottle line via a bypass. This option is used in situations where the
numerous packaging options offered by the one-way glass bottle line are to be
utilized for refillable bottles. Another option: after the filling process, non-refillable
bottles can be sent to the KHS refillable bottle line. The one-way glass bottle line is
able to pack filled and labeled bottles into more than 40 different packaging units,
including traditional cartons, cluster packs, wrap-around packaging, tray packaging,
and tray shrink packaging. The line also offers to combine different packing stages.
Usually, bottles initially enter either an Innopack SP 060 shrink packer from KHS
Kisters or a multipacker, from where they continue to a wrap-around tray shrink
packer. In the APB installation, wrap-around packs, tray packs, and tray shrink packs
are set up from pre-formatted units. Bottles may also be sent individually to the wraparound tray shrink packer or inserted in tray shrink packs, wrap-around packs, or tray
packs as part of predefined units (24-packs for 0.33-liter bottles, 12-packs for 0.64liter bottles). Likewise possible: bottles can be sent directly to the Innopack PPZ
cyclic caser, which packs the units in cartons. In general, an almost infinite range of
options is available when it comes to packaging. Whatever packaging decisions APB
will make in the future, the new lines are well prepared. In order to make full use of
the flexible packaging technology, in addition to the refillable glass bottle line an
existing canning line was also connected to the advanced packaging section of the
new one-way glass bottle line from KHS. If required, a wide range of can packaging
options can also be implemented. The palletizing technology downstream of the
packaging process within the one-way glass bottle line is also well prepared for
handling a virtually unlimited variety of options. Two fully automatic Innopal PL
gantry-type palletizers ensure maximum flexibility. Finished packs are put into
formation and pushed onto the pallet by means of a perforated plate. This ensures
gentle handling of the product. An Innopal MS pallet magazine regulates the supply
of pallets. The palletizers can automatically be adapted to different product formations at the push of a button.
Both the one-way glass bottle line and the returnable glass bottle line are equipped
with the AIS Plant Information System. AIS is a PC-based data acquisition system
that records the operating conditions of the line and provides information on the
entire line and the status of the individual machines ready for retrieval at all times.
Weak points and malfunctions can be quickly identified to increase productivity. A
seamless documentation of processing data for quality assurance purposes is
granted. Costs can be classified and minimized by controlling the energy and media
consumptions. With AIS, it is not only feasible to monitor a line's status but also to
document and compare parameters over extended periods of time.
Alan Gourdie, General Manager, APB Singapore, comments: "The new line offers us

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greater flexibility in packaging our beers without having to suffer repeated downtimes
when we undertake changeovers. This result in an improvement in the packaging
line efficiency and allows us to respond more effectively to market demands. Given
the flexibility and the enhanced capabilities of the lines, APB will be able to seamlessly tap on market opportunities that can boost our operations.

Customer's Benefit

High flexibility, short changeover times, and minimum operator dependence.

Prevention of interface problems.

Plant efficiency enhanced by ease of operation, low maintenance, and assurance
of optimum hygienic conditions.

Low-oxygen pick-up filling.

Advantage of multiple caustic baths by double-end bottle washing technique.

Short product and bottle changeover, high machine availability.

Specific line interchange contingency.

Ordering Party

Asia Pacific Breweries Ltd., founded 1931 in Singapore as a joint venture between
Fraser & Neave Ltd. (F&N) and Heineken N.V., produces and markets more than 40
beer brands, such as Tiger Beer, Heineken, and Guinness. APB owns 21 breweries
in Singapore, Vietnam, Cambodia, New Zealand, Papua New Guinea, Malaysia,
Thailand, and China. APB EBIT in 2004 reached US-$ 104,8 Millionen. Major
stakeholders are F&N, a leading Asian foods and beverages company with 37,9 %,
and Heineken, an brewery group operating in more than 170 countries, with 42,5 %.
Internet: http://www.apb.com.sg

Contractor

KHS Maschinen- und Anlagenbau AG, Dortmund, is an international manufacturer

of filling and packaging systems for the beverage, food, and non-food industries.
KHS was founded 1993 by the merger of Holstein & Kappert AG and Seitz-Werke
GmbH alias SEN AG. KHS is a subsidiary of Klckner-Werke AG, a renown
engineering company, again belonging to the WCM Group, which holds a stake of
78%. KHS posted sales of 700 million in 2004 with a world-wide staff of 3.200.
Internet: http://www.khs-ag.com
Contact: Manfred Rckstein, Head of Communications
KHS Maschinen- und Anlagenbau AG, Juchostrasse 20, 44143 Dortmund
Tel.: (+49 231) 569-0
Fax: (+49 231) 569-1339
E-Mail: rueckstein.manfred@do.khs-ag.com

drinktec 2005

Every four years drinktec presents an international range of products and services in
the area of beverage technology. The special aspect of drinktec is that is offers the
right technology, raw materials and logistics solutions for every type of beverage and
liquid food. drinktec 2005 offers the full range of technologies, whether for manufacturing, filling or packaging purposes, and regardless of the cultural setting the drink
comes from. The exhibiting companies will be presenting technologies and system
solutions for the complete production area covering the total value-added chain
from manufacturing to the distribution of non-alcoholic drinks, beer, spirits, milk and
milk mix drinks, yoghurt-based drinks, fruit juices, wine and waters, tea and coffee,
energy and wellness drinks, edible oil, and all other beverages and liquid foods.
Contact: Johannes Manger, Head of Project Communications, Business Unit 4
Messe Mnchen GmbH, Messegelnde, 81823 Munich
Tel.: (+49 89) 949-20630
Fax: (+49 89) 949-20639
E-Mail: johannes.manger@messe-muenchen.de
Internet: http://www.drinktec.de