The German FFS manufacturer from Dortmund is and always has been focusing on developing sustainable containers with an attractive design, adopting a holistic approach to the manufacture, filling, labeling and packaging of PET containers throughout the entire filling and packaging line.
Packaging MEA (PMEA): KHS is spearheading initiatives in the – in sustainability and digitalisation at the Gulfood show. Can you explain what are they?
Meinhar Fischer (MF): In terms of sustainability we have made a lot of efforts especially for our PET bottling lines. To reduce the amount of energy we are using for blow molding process. So with our current blow mold series 5, I think it is the lowest energy consumption per bottle you can find in the market.
Even with our series 4 we already had a reduction by 30% and we now further reduced it by 30% – the energy consumption per blown bottle. We are also looking in our other machines after blow molding to reduce the energy by using modern drives in the conveyors to reduce the energy, which is needed there – permanent magnet motors.
We looking at all the possibilities to reduce the energy because the life cycle process of a complete bottling line is becoming more and more important for our customers. Example in a retainable glass bottling line, which are not so common here in the region but in Africa a lot of effort is put in our bottle washing machine to reduce the usage of energy and water.
PMEA: What do you see as a trend and perspective in the Middle East regarding single-use plastics? How is KHS as a company preparing for that?
MF: We have developed two different things. One is the use of reusable plastic. The market in Germany we have come up with a bottle, which is 100% PET, and is recyclable to give our customers to have a bottle, which takes care of the recycling aspects and also costs. The Bottle concept provides maximum product protection for sensitive beverages and is fully recyclable thanks to FreshSafe PET® technology.
PMEA: Is this mechanically recycled PET or chemically recycled PET?
MF: Mechanically recycled PET.
PMEA: How sensitive are the consumers/brand owners in the region and are open to the idea of implementing recycled material?
MF: The customers in this region are compelled by the authorities or their big customers because they want to reduce the amount of plastic garbage. There is no recycling system in this region like we have in parts of Europe where there is a good functioning recycling system. They are looking at avoiding plastic bottles as there is no proper recycling system in place. Some of the customers have been proposing/asking products, which were supplied in PET bottles to be made available in cans.
PMEA: As an organisation how is KHS preparing for that? Are you contemplating promoting can lines in the area?
MF: We are working towards making solutions available for our customers. We are not promoting can lines or any alternate lines. We have a solution for our customers and we are working on developing further solutions so that we are prepared for the future.
PMEA: Where is KHS and how far down the road are they with predictive maintenance monitoring of the assets around the world continuously and suggesting what needs to be fixed before disaster strikes?
MF: We have a complete system implemented in our lines and also in a single machine for a remote diagnosis to help our customers in case of an error or failure they can’t solve by themselves. On the other hand we have the spare parts on a web-based portal where the customers can order the spare parts by themselves. In some machines, we have a spare part catalogue available on the HMI and we are also working on solutions for maintenance check, for instance, measuring the vibration of the bearings.
PMEA: Any new innovations in terms of machine capabilities or upgrades or any particular case study you would like to speak about?
MF: We have developed a package wherein we can glue together 6 cans. This is called Nature Multi Product (NMP). This is already in the market. These cans don’t need any carton or film and is palletised. This is a great success with one of the European beverage companies.
PMEA: Has this been readily adopted by customers?
MF: We are sold out for the next two years for this particular pack format. We also have a pack fully enclosed which is for cans and bottles. We have a 24 pack of cans which is fully enclosed on the sides which makes it very stable and you don’t need a tray.
PMEA: The KHS’ barrier technology that you are promoting. How is that different from everybody else in the industry?
MF: This is our plasma coating technology where we inject a gas into the bottle and then we ignite this gas with microwave. It is not a gas but a plasma, which is ignited and as a result, there is a small explosion. Due to this there is a small layer of glass deposited on the inside of the bottle, only a few microns thick. This small layer increases the barrier capability of the bottle from the shelf life of approximately six weeks to six months. In India one of our customers is very successful with a small bottle – 200 ml. Smaller the bottle, more strained is the relation between volume and surface. With this technology normally in such a small bottle after two weeks the CO2 is already reduced. With this technology there is no problem after six months.