Partnership for Success with KHS Service
The Karlsberg brewery opts for first-class filling and packaging technology for highly efficient, durable lines
Jürgen Vandree* Jürgen Thielen** "Partnership brings success" is the motto of the Karlsberg Group: a motto that clearly reaches out beyond the Group itself. An example of a successful partnership is the long association stretching back over decades between Karlsberg Brauerei and KHS. This is a partnership in which Karlsberg regards KHS as much more than just a supplier of filling and packaging technology. Bernd Franzmann, manager of machine technology, maintenance, and environment at Karlsberg Brauerei GmbH, comments, "Since the 1960s KHS has been providing us not only with high-quality line equipment but also with the kind of support that contributes to both the long service life and the high efficiency of our KHS lines. We regard KHS as a partner whom we have always been able to rely on in the past and will always be able to rely on in the future." Karlsberg Brauerei the heart of the Karlsberg Group Founded in 1878, Karlsberg Brauerie lies at the heart of the Karlsberg Group which operates in various core commercial areas today. As well as beer, the companies belonging to the Karlsberg Group market beverages and services relating to all aspects of everyday enjoyment, from fruit juices and soft drinks to transport services and events management. This means they occupy areas of the market that are geared towards both the future and towards success. Their aim is to impress customers with their efficiency, quality, and innovative drive so as to secure customer loyalty, which is part of their corporate strategy. Deliberately developing the different branches of the company to create a powerful network of expertise not only enables optimum market penetration; it also represents genuine added value for their customers, employees, and partners. * Service manager, Market Zone Europe, KHS GmbH. Phone: +49 (231) 569-1851 ** Senior service engineer, KHS GmbH. Phone: +49 (231) 569-1543 National and international focus By acquiring a block of shares in the Überkingen-Teinach AG (MinAG) mineral water company in 2001, Karlsberg added some of Germany's leading mineral and spa water brands to its portfolio, including Staatlich Fachingen, Hirschquelle, and Teinacher. The acquisition of Tucano Holding, now a MinAG subsidiary, enables the brewery to achieve pioneering synergy effects in the production of mineral water, soft drinks, and fruit juices. Tucano Holding owns the Merziger, Niehoffs Vaihinger, and Klindworth fruit juice brands. The strong Nestlé Schöller ice cream brands are a guarantee of quality for Karlsberg subsidiary TKZ Tiefkühlkost-Zentrale. Moreover, the partnership with Brasserie Licorne makes the Karlsberg Group the only brewing company in Germany with production facilities in France as well. Production at the French brewery subsidiary focuses on supplying retail brands in innovative containers and packaging to the large French commercial centers around the world. Pole position for mixed beer beverages In 1996 the Karlsberg brewery could well have been following another of the Karlsberg Group's guiding principles, namely "exploit the efficiency of anti-cyclical behavior", when it went into action. Not only did it become a pioneer in the mixed beer beverages segment by starting to sell Desperados Tequila flavored beer; it also developed Karlsberg's own mixed beer beverage brand MiXery Bier + Cola + X. As so often with Karlsberg, this kind of pioneering strategy has paid off, a fact which current market data as well as other sources confirm. With a 30% market share, MiXery Bier + Cola + X remains the number one beer-and-coke beverage on the German market according to the global marketing research firm ACNielsen. "This is a position in which we do not intend to sit back and take things easy", adds Jens Wimmermann, manager of Karlsberg's national brands. In the same vein Karlsberg Brauerei has continued to make waves on the market since the start of 2011 when it launched a new iced version of MiXery Bier + Cola + X which is sold in either a 0.33-liter white glass bottle or a 568-milliliter can (a British pint), also a new introduction to the market. Quality remains paramount Its beer brands indicate that Karlsberg is very much a regional concern. Recently awarded a gold medal for its high standard of quality by the German Agricultural Association, the DLG, classic Karlsberg UrPils is still the region's top beer brand. According to Dr. Hans-Georg Eils, engineering and logistics manager at Karlsberg Brauerei GmbH, "The German Agricultural Association award shows that our policy of focusing on quality and using first-class raw materials is absolutely right." The company also markets a wide range of beer brands where the focus is likewise on quality, as indeed it is with all the beverage brands produced by the Karlsberg Group. These include UrPils light, Feingold, Gründel’s non-alcoholic beer, Pils, Export (a pale lager) and Bockbier (a strong, dark beer). New products and containers in line with current trends are constantly being added to the standard range. One example is the latest addition of Karlsberg Weizen (wheat beer) which comes in four varieties: Hefetrüb (with a slight yeast haze), Dunkel (dark), Kristall (crystal clear), and Alkoholfrei (non-alcoholic). Karlsberg's approach is to produce an unusually wide variety of beers and beverages so as to ensure that every single customer, whatever their age, will find the product they want. A wide variety of filling and packaging systems for a wide variety of products A wide variety of products reflected in a range of very different containers inevitably requires filling and packaging systems which are as varied as they are flexible in terms of how they adjust to the different containers used. As a result not only two glass bottling lines but also a keg and a canning line are currently in use at the Karlsberg brewery, all three equipped with KHS machines for the most part. The latest investment in a KHS glass line took place in 2007. Like the KHS glass line commissioned in 1991, the 2007 line achieves an output of 60,000 glass bottles an hour. Both lines process 0.33 and 0.5-liter glass bottles. The 1996 KHS canning line has a filling capacity of 70,000 cans an hour and is equipped for 0.33, 0.5, and 0.568-liter cans. The capacity of the KHS keg line, which fills 15, 20, 30, and 50-liter kegs, is 360 kegs an hour. Increased line availability thanks to a highly skilled workforce and KHS service Franzmann comments, "Besides its enormous flexibility, the increased availability of our line equipment is also of paramount importance. This increased availability is achieved thanks to our deployment of a highly skilled workforce and the comprehensive service provided by KHS." A comprehensive service package Comprehensive KHS services have been a feature at Karlsberg for as long as KHS equipment has been used by the company – that is, since the 1960s. KHS service includes regular consultations, regular overhauls of KHS equipment, a rapid response in the event of an emergency, implementing any required conversions, transferring updates, and remote maintenance by means of ReDiS (Remote Diagnostic Service). On average, KHS contacts Karlsberg every two weeks. Consequently, any issues can be clarified quickly, any necessary action taken promptly, and any orders for spare parts discussed in detail before being placed. Regular overhauls the norm Regular overhauls are crucial for the availability of KHS lines and thus take place about once a year at Karlsberg. KHS preparation for the requested overhauls includes first compiling an inventory of any spare parts required. This in turn involves noting the precise condition of the existing parts as well as how long they have been in use. Particularly helpful when compiling the inventory are the spare part codes that provide information on how many hours the individual parts are expected to remain fully functional. KHS engineers complete an inventory of spare parts on site and online. Based on the online data received, KHS prepares a quote for Karlsberg Brauerei which – and this Franzmann finds indispensable if the partnership is to function effectively – can be renegotiated in detail, drawing on the extensive expertise of KHS. Technology put through its paces The Karlsberg brewery allows approximately two weeks for the annual overhaul of its KHS equipment. Within this time frame all the machines in all the necessary places are almost totally stripped down to their individual components. For example, in the filler area one of the many tasks is to dismantle and take apart the filling valves, the product and gas controllers, and the probe adjustments, and so on. An essential part of this process is to examine all the critical points of every single machine extremely carefully. Basically, a successful overhaul leaves nothing that has not been put through its paces. Overhauls at Karlsberg are carried out by both KHS engineers and Karlsberg's own employees. Hans-Jürgen Peter, master electrician for planning, maintenance, and filling at Karlsberg Brauerei GmbH, comments, "The advantage here is that operating personnel become even more familiar with the individual components of the line, acquiring the expertise which will enable them to provide a more accurate assessment of any line problems arising in the short term while the line is actually operating." As far as overhauls are concerned, bottle washers are generally an exception. Although they are always included in the annual overhaul, their chain tensions are subjected to an additional test every three months. The reason is that the chains can stretch, causing considerable damage inside the machines as a result. The torques of the individual drives are continuously monitored, giving the operators additional information on the actual status of the chains at all times. High efficiency guaranteed Franzmann explains, "We basically owe the increased availability of our lines to these regular overhauls. It's these that prevent problems arising in the first place, making sure that even our older lines achieve extremely high outputs. Both the KHS glass lines and our KHS keg line have an efficiency of over 80%. Our KHS canning line has an efficiency of more than 90%.” These are outstanding values which, as Franzmann says, Karlsberg depends on. Storage space is limited and, as a result of the brewery's considerable diversity of products, operations are carried out using a relatively small supply of the different containers. This means the machines have to keep on running, and running, and running, usually operating in three-shift cycles, less often in two. "And they do," says Peter. 24-hour hotline However, should short-term problems arise in spite of all these preventative measures, Karlsberg can access the KHS hotline 24 hours a day – another major benefit, according to Peter. ReDiS also involved Another feature of the KHS service package which Karlsberg can use for the latest 2007 KHS glass line and its cutting-edge control components – and one it uses with complete confidence – is ReDiS or Remote Diagnostic Service. If problems with KHS machines occur, a link to the KHS ReDiS service center is quickly established. Access to the controls of the relevant machine makes it possible to carry out a remote analysis immediately. Ideally, setting up online access to the electronic system components is usually enough to solve the machine problem in question. If the problem involves mechanical components, the engineer at the machine is notified as to precisely which steps to take. Reprogramming a machine or transferring possible updates via ReDiS is also conceivable, besides providing prompt support. All told, this system also makes a considerable contribution towards increasing line availability. According to Franzmann, "For highly automated lines like our 2007 KHS glass bottling line, ReDiS is essential for efficient line operation.” Peter adds, "We've already benefited from KHS support through ReDiS on more than one occasion. This is just one of the reasons why our employees, although skeptical at first, are now in full favor of this system.” Filler conversion pays off fast KHS' conversions service is especially important for the older KHS lines. Only recently a complete overhaul at the Karlsberg brewery by KHS included converting the filling valves of the KHS can filler acquired in 1996. As a result, the filling volume could be set with greater precision and any oxygen pick-up in the product was minimized. This conversion measure alone has since enabled Karlsberg to achieve values identical to those of a new, mechanically-controlled KHS can filling system. As Franzmann puts it, "The investment will pay for itself in less than two years. The very fact that it is now possible to set the filling volume accurately means overfilling is no longer necessary and we save product. Then there's the enhanced product quality thanks to the lower oxygen pick-up. Like so much of the work already carried out I consider conversions such as this to be a win-win situation." Software update for servo technology in the bottle washing machine In addition, a servo technology software update was implemented on the 2007 bottle washing machine at the Karlsberg brewery just recently. This brought about various improvements in machine functions, which in themselves make the system easier to operate. As a general rule, whatever is feasible in terms of conversions and updates which will enable Karlsberg filling and packaging technology to become truly cutting edge is discussed between KHS and Karlsberg – and either rejected or implemented. As a matter of principle Karlsberg Brauerei is never left to make a decision alone; on the contrary, KHS is always ready to provide various options for and against, therefore providing a sound basis upon which the brewery can make a decision. Right now Karlsberg is considering converting a 1995 packaging machine to new control technology which is still under discussion with KHS. Exceptionally long service life According to Franzmann, "It's the excellent training of our line operators on the one hand and KHS' comprehensive service provision on the other that guarantee the exceptionally long service life of our KHS filling and packaging lines. And we're talking about at least 20 years here." Sustainability with KHS – the issue of the future Franzmann strongly believes that in the future any investments in engineering will be considered not only in terms of line availability, easy operation, and cost cutting, but also increasingly in terms of sustainability. Using resources sparingly has long been a guiding principle for Karlsberg, intent on becoming a 'green' brewery. Franzmann concludes, "Having KHS as a partner who not only supplies technical systems of outstanding quality but also optimizes machine and line equipment in terms of sustainability means we can continue to map out the best long-term routes towards our goal of environmental conservation in filling and packaging technology in the future, and that we can both achieve this successfully." That these routes will generate a win-win situation for both sides and ultimately remain true to the Karlsberg motto of 'Partnership brings success' goes without saying.
