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Case Study

KHS Maschinen-und Anlagenbau AG

Asia PacificBreweries Ltd.

Weltmesse Nr.1 fr Getrnke- Messe Mnchen GmbHund Liquid Food Technologie Messegelnde

Mnchen81823 Germany

New Munich Trade Fair Centre

12.-17.9.2005Phone (+49 89) 949 11318Fax (+49 89) 949 11319

World Fair No.1 for Beverage info@drinktec.deand Liquid Food Technology www.drinktec.de

Categories 1. Plant and machinery for beer production, malting and silo technology2. Cleaning, filling and sealing machines for bottles, cans, soft packs, kegs,

casks and other containers3. Inspection and sorting machines, monitoring equipment4. Etikettier-, Ausstattungs-, Druck- und Signiermaschinen

5. Unpacking & packing machines / multiple packing machines6. Palletising, depalletising and discharging equipment, conveyors andintermediate storage, order picking equipment

7. Cleaning, disinfection and sterilisation systems, dust removal systems8. Computing, IS and IT solutions, documentation

Market Sector Breweries

Task Delivery and implementation of plant and equipment for one KHS one-way bottlefilling line and a KHS returnable bottle filling line for the APB-plant in Singaporewithout 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 existinglines. A maximum of two weeks production interruption for each line was allowed.

This necessitated several installation phases, which were all based on the followingscheme: first step - removal of parts of the existing line equipment and integration ofnew machine equipment, without actually replacing any units. Second step: thoroughtesting of the new machine equipment, followed by the final step involving integrationinto the line and removal of old electronic components. The staged introduction ofnew components was scheduled according to plan based on the available space.Things worked out well: production was not interrupted once during the configurationand testing phases.

Implementation Asia Pacific Breweries Ltd., one of the largest South East Asian breweries, saw theneed to accommodate rising demand for their brands by expanding their productionfacilities in Singapore. They asked KHS Maschinen- und Anlagenbau AG to buildand assembly two new filling lines.

Today, both one-way glass and returnable glass bottle lines operate in three shiftswith a capacity of 24,000 0.33-liter glass bottles per hour and 18,000 0.64-liter glassbottles per hour respectively. Both lines are designed for filling the desired range ofAPB products in a wide range of container types. Both lines are additionally

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

Technical Innovation Leadership through advanced KHS PlantEngineering for Multiple Shift Production at Asia Pacific Breweries

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characterized by high flexibility, short changeover times, and minimum operatordependence. The one-way glass and returnable bottle lines can also operatetogether whenever necessary and possible. The flexibility of the lines also link withthe existing canning line such that cans can be packed with a similar configurationusing the new innovative equipment from the bottle lines.

One of the two Innopal AS new glass depalletizers installed directly adjacent to eachother within the lines deals with the returnable glass bottle line. If the quantity of

returnable glass bottles is insufficient, this new glass depalletizer automaticallysprings into action. The second new glass depalletizer continuously supplies theone-way glass bottle line with new glass bottles. Both depalletizers achieve fullnominal line capacity. If necessary, the Innopal AS provided for the returnable glassbottle 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 thetask of palletizing and depalletizing crates. The Innopal RS3 is a multiple-stationpalletizing robot with a working radius of 180. This means versatility and flexibilitywithin a minimum amount of space. A special advantage of the Innopal RS3: thepalletizing and depalletizing processes only require a single clamping head each.The heads can easily be adjusted when the line is changed over to a differentcontainer type. Here too, changeover times are confined to a minimum.

Two Innopack RS column-type robots take care of crating and decrating. Thepacking heads of the crater as well as the decrater are changed fully automaticallywhen changing the type of crates and/or bottles. Both column-type robots havebeen designed to place the current packing head and correction frame in the spaceprovided 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 ofthe feed table is also replaced. A process that also takes only a few minutes tocomplete.

The KHS modular dry area concept is highly intelligent solution as control is handledby a single PC-based computer. Unlike conventional control concepts, this solutionuses a single intelligence approach for transferring information to all other systemcomponents via modern bus equipment thus ruling out all interface problems.Possible trouble spots can be pinpointed immediately. Direct, real-time communica-tion links and computer-controlled sequences of motion guarantee high cycle timesand maximum precision when scanning travel profiles entirely without sensorcomponents. Another advantage of the modular KHS design: horizontal and verticalmovements are generated exclusively by cog belts. This means maintenance-freeoperation in addition to lower noise levels. Servomotors shorten cycle times andensure high performance coupled with exact adherence to the so very importantpositioning accuracy. Within the returnable glass bottle line, decrated glass bottlesare sent to the Innoclean DM double-end bottle washer. The crates are sent to theInnoclean KW crate washer and subsequently either to the crater or to a cratemagazine 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) andconsistent separation of the dirty bottle infeed and clean bottle discharge. Moreover,graduated temperatures and concentrate levels can be adapted to the particularstyle of bottle. For APB this graduation is significant, not only because of the widerange of bottle styles that are used, but also because at times of low returnable glassbottle availability complete batches may be filled in new glass bottles. AdvancedKHS cleaning technology adapts the cleaning program individually to new glassbottles. The bottle washer is additionally equipped with Triple-i-Drive technology.This Triple-i-Drive technology minimizes the time required for changeover to a widerange of different bottle styles. Once the last bottle has entered the machine, theinfeed can be completely disengaged from the drive. Changeover work can beginwhile the bottle washer is running. The same is true for changing over the dischargeto new container shapes.

The filling system in operation for returnable glass bottles is a computer-controlledInnofill DRS-ZMS pneumatic pressurized filling system that operates with filling levelprobes. The filling process is preceded by double pre-evacuation and double CO 2purging. Exact filling levels are determined by filling level probes. The advantages ofthis 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-dependentprocessing sequences, adaptation of the filler output to the output of the particularline, and the extremely low-oxygen filling process. The microbiological filler fronttable ensures maximum microbiological hygiene in the vicinity of the filler.

Following the filling and capping process, processing continues in the single-deckInnopas PI pasteurizer. The pasteurization process is constantly monitored andoptimized by an integrated PU control system. A computer, linked with the pasteuri-

zation process indicates actual product temperatures and infeed pasteurization unitsbased on the treatment time and continuously measured spray temperatures in eachof the zones. Any necessary control actions can be carried out quickly based on theinformation gathered.

Regarding the labeling equipment, the returnable glass bottle line uses an InnoketKL 2080. In this specific installation, the Innoket 2080 is equipped with three labelingstations. The labeling stations can apply the following label types as required:shoulder, body, neck, and back labels and aluminum foil over crown corks. Ease ofoperation, low maintenance, and assurance of optimum hygienic conditions are thekey features of the Innoket KL 2080 labeler. This generation of labelers is equippedwith automatic vertical head adjustment so that no manual work is required forpossible bottle style changeovers. The labeling stations operate according to theprinciple of rotation, using the electronic VarioDrive bottle turret control.

After the labeling process, the returnable glass bottles are usually sent to the craterand palletizer. It is also possible, however, to feed the bottles to the new KHS one-way glass bottle line via a bypass. This option is used in situations where thenumerous packaging options offered by the one-way glass bottle line are to beutilized for refillable bottles. Another option: after the filling process, non-refillablebottles can be sent to the KHS refillable bottle line. The one-way glass bottle line isable 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 KHSKisters or a multipacker, from where they continue to a wrap-around tray shrinkpacker. In the APB installation, wrap-around packs, tray packs, and tray shrink packsare set up from pre-formatted units. Bottles may also be sent individually to the wrap-around tray shrink packer or inserted in tray shrink packs, wrap-around packs, or traypacks as part of predefined units (24-packs for 0.33-liter bottles, 12-packs for 0.64-liter bottles). Likewise possible: bottles can be sent directly to the Innopack PPZcyclic caser, which packs the units in cartons. In general, an almost infinite range ofoptions is available when it comes to packaging. Whatever packaging decisions APBwill make in the future, the new lines are well prepared. In order to make full use ofthe flexible packaging technology, in addition to the refillable glass bottle line anexisting canning line was also connected to the advanced packaging section of thenew one-way glass bottle line from KHS. If required, a wide range of can packagingoptions can also be implemented. The palletizing technology downstream of the

packaging process within the one-way glass bottle line is also well prepared forhandling a virtually unlimited variety of options. Two fully automatic Innopal PLgantry-type palletizers ensure maximum flexibility. Finished packs are put intoformation and pushed onto the pallet by means of a perforated plate. This ensuresgentle handling of the product. An Innopal MS pallet magazine regulates the supplyof pallets. The palletizers can automatically be adapted to different product forma-tions at the push of a button.

Both the one-way glass bottle line and the returnable glass bottle line are equippedwith the AIS Plant Information System. AIS is a PC-based data acquisition systemthat records the operating conditions of the line and provides information on theentire 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 isgranted. Costs can be classified and minimized by controlling the energy and mediaconsumptions. With AIS, it is not only feasible to monitor a line's status but also todocument 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 downtimeswhen we undertake changeovers. This result in an improvement in the packagingline efficiency and allows us to respond more effectively to market demands. Giventhe flexibility and the enhanced capabilities of the lines, APB will be able to seam-lessly tap on market opportunities that can boost our operations.

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 40beer brands, such as Tiger Beer, Heineken, and Guinness. APB owns 21 breweriesin Singapore, Vietnam, Cambodia, New Zealand, Papua New Guinea, Malaysia,Thailand, and China. APB EBIT in 2004 reached US-$ 104,8 Millionen. Majorstakeholders 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 manufacturerof 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-WerkeGmbH 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 of78%. 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 CommunicationsKHS Maschinen- und Anlagenbau AG, Juchostrasse 20, 44143 DortmundTel.: (+49 231) 569-0Fax: (+49 231) 569-1339E-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 theright technology, raw materials and logistics solutions for every type of beverage andliquid food. drinktec 2005 offers the full range of technologies, whether for manufac-turing, filling or packaging purposes, and regardless of the cultural setting the drinkcomes from. The exhibiting companies will be presenting technologies and systemsolutions for the complete production area covering the total value-added chain from manufacturing to the distribution of non-alcoholic drinks, beer, spirits, milk andmilk 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 4Messe Mnchen GmbH, Messegelnde, 81823 MunichTel.: (+49 89) 949-20630

Fax: (+49 89) 949-20639E-Mail:johannes.manger@messe-muenchen.deInternet:http://www.drinktec.de

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 assuranceof 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.