Sustainability report 2017/18

Our primary goal at all levels: resource conservation

Whether in the design, production, transport or commissioning of our filling and packaging solutions, no matter what requirements you place on us as an expert in container and packaging solutions: for us, as one of the leading developers of innovative solutions in our branch of industry, resource conservation is an important goal in every (further) development.

Our core competence involves developing product and service solutions for our customers that innovatively combine quality requirements, individual customer requirements and sustainability goals. At the same time, the various aspects of a high-performance offer are mutually dependent: packaging, machine and service products are mutually influencing; their further development leads to the next development steps. This means that we are able to offer conversions and upgrades for a great number of existing machines in the short-term so that they can be upgraded technically, economically and ecologically. This way, we provide our customers support so that in the long term they can work with a reliable and cutting-edge filling and packaging systems. Our sales and service locations in more than fifty countries around the world support this claim, ensuring that the creation of value over the life cycle of the system continues as expected - or even increases - while minimizing the consumption of resources and maximizing system efficiency.

One of the most important goals in the development of innovative filling and packaging systems is the long-term reduction of CO2 consumption from two different standpoints: in the manufacturing processes of our customers as well as all aspects of the packaging they choose for their product range. To achieve this goal, numerous aspects have to be taken into account which KHS has actively addressed in recent years. This has resulted in the launch of a large number of innovative new and further developments to the market in 2017 and 2018 presented below.

5-gram lightweight presented to the market

Our expertise in lightweight containers is defined by sophisticated technology and not only ensures that our customers save considerable costs, but sustainably improve their ecobalance. This was how the concept of weight optimization of the 100 bottle factor came into being, for example. We presented this concept at 2017 drinktec. Based on this concept, we have further reduced the weight of a 0.5-liter PET bottle for still water to only 5 grams (without the cap). We saved 2.2 grams of weight versus the 7.2 grams of the 0.5-liter PET bottle generally available on the market. The CO2 equivalent alone is approximately 30% higher than the other bottle type.

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rPET bottle made of 100% recycled PET

For our customer share, we developed the first 0.5-liter and 1.0-liter bottles made entirely of recycled PET, which, introduced in September 2018, saves a CO2 equivalent of about 40% versus comparable bottles made of virgin PET. Using 100% recycled materials for PET bottles is a real innovation. share is the first German company to launch a bottle to the market made of 100% rPET and thereby sets a good example by paving the way to a complete packaging cycle. Henkel also followed up in 2018 and now produces all its PET bottles from recycled PET.

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FreshSafe-PET®: International breakthrough of the barrier solution

Take the best properties of PET and glass and combine them into one of the most sustainable product developments in the industry: FreshSafe-PET®. An ultra-thin protective layer of silicon oxide (SiOx) - chemically pure glass - applied to the inner walls of the PET container forms an effective barrier to protect and ensure the shelf life of the product. The lighter weight versus the glass bottle offers a much improved carbon footprint and extends the product shelf life by up to ten times thereby avoiding environmentally harmful food waste.

A really unique selling point is that FreshSafe PET® bottles are 100% recyclable. This feature is in keeping with the spirit of the times when society is raising the question of how plastic waste can be avoided in favor of a sustainable circular economy. FreshSafe-PET® solves this dilemma in an intelligent way: it completely replaces the otherwise necessary additives needed to achieve such high product protection.

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Block system for efficient production

In 2017, we made a major contribution to greater energy efficiency in production by offering options for combining our customers' machinery to form a blocked system. The InnoPET TriBlock and InnoPET FreshSafe TriBlock block systems have been successfully introduced to the market.

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The InnoPET Blomax Series V stretch blow molding system uses up to 40% less energy

In 2018, we significantly enhanced our successful high-performance stretch blow molder. Depending on heater version our customers choose, the Series V InnoPET Blomax is able to reduce the energy consumption by up to 40%. This also results in a corresponding reduction in CO2 emissions depending on the energy mix used.

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Retrofitting the stretch blow molder heater to state of the art

We have been offering our customers a service for upgrading their heaters to the state of the art of the new InnoPET Blomax Series V stretch blow molder since 2018 to enable them to heat preforms in accordance with current standards. Depending on the heater version and on the energy mix used, energy savings of up to 40% are possible in addition to lower CO2 emissions.

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Innofill Can C for smaller breweries

In 2017, we customized our can filler to the requirements of small and medium-sized breweries. A positive side effect: with the Innofill Can C we were able to reduce CO2 emissions by up to 30% - with the same oxygen pickup - compared to the competition.

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Innopas SX: Thermal energy-saving pasteurizer

We launched the new Pasteur Innopas SX to the market in 2017. It is hallmarked by its ability to offer significant heat savings while delivering process optimization that results in improved overall product quality.

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Innopack TLM block system reduces energy consumption

With the Innopack TLM block system, we included a very flexible packaging system in our product portfolio in 2017, which can process a wide variety of different types of secondary packaging. By eliminating the need for the shrink tunnel of the SP packer, this system conserves resources and decreases the energy consumption by about 70% in addition to generating less CO2 depending on the energy mix used.

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Film-free Nature MultiPackTM convinces Carlsberg

One of the most sustainable innovations in secondary packaging is based on our principle of "thinking outside the box": creative and unusual ideas and approaches have a permanent place at KHS. This is how the new Nature MultiPack™ came into being. It is a pack that holds PET bottles or cans together solely by dots of adhesive and requires no film wrapper of any kind.

In 2018, we acquired a key customer in the beverage can sector - Danish brewer Carlsberg. Since Calsberg also publicly advertises its firm belief in the merits of resource-saving innovations, Nature MultiPackTM is enjoying considerable popularity and is increasing its degree of familiarity enormously. Compared to ordinary six packs and film-wrapped packs, this innovation with adhesive dots saves up to 79% on CO2 emissions.

Innofill Glass DPG ECO reduces CO2 and energy consumption

In 2018, we further developed our proven filling process. As a result, we can now offer our customers significant CO2 savings of up to 50% in the filling process - coupled with maximum technological quality - with the Innofill Glass DPG ECO. In addition, we have achieved additional 20% savings in electrical power required for vacuum generation.

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Innopas SX: Thermal energy-saving pasteurizer

We launched the new Pasteur Innopas SX to the market in 2017. It is hallmarked by its ability to offer significant heat savings while delivering process optimization that results in improved overall product quality.

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Compact and efficient: Innoket Roland 40

Great success in a small format: A compact version of our Innoket Roland labeling system for small and medium-sized breweries has also been available since 2017. A resource and energy-conserving as well as space-saving system for customers.

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Innopack TLM block system reduces energy consumption

With the Innopack TLM block system, we included a very flexible packaging system in our product portfolio in 2017, which can process a wide variety of different types of secondary packaging. By eliminating the need for the shrink tunnel of the SP packer, this system conserves resources and decreases the energy consumption by about 70% in addition to generating less CO2 depending on the energy mix used.

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Service for optimized glass bottle filling

Our glass bottle filling systems can be optimized significantly with the ECO vacuum pump and the camera-controlled OPTICAM inspection system. The ECO vacuum pump uses less water and decreases water consumption by up to 95%. Thanks to these savings and the lower costs of supplying raw water, for example, or the subsequent water treatment process, we also indirectly achieve a reduction in CO2 emissions. The OPTICAM camera system ensures significantly lower product losses and thus also indirectly for more resource and CO2 efficiency.

Innokeg Transversal: many options within a small footprint

In 2017, we successfully introduced our extendable keg system for all types of treatment in the washing and racking processes. By using the new IE4 generation of electric motors in the conveyors we have reduced the power consumption even further. In addition, the machine uses water twice by utilizing the rinse water as mixed water for pre-washing and thus saves on valuable resources.

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Media valves for less maintenance

Valves for controlling cleaning media for keg treatment that have been available to our customers since 2018, reduce maintenance costs significantly and thereby increase the system availability.

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Upgrade for product-specific filling

With our software-controlled, product-specific Direct Flow Control (DFC) filling system, our service offers customers precise and gentle racking to meet every requirement. This upgrade system, which has been successfully implemented for decades, uses up to 40% less CO2 by reducing the pressurization pressure prior to the racking process.

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