This document is property of

Line design the krones Group and

contains confidential
information.

“the most appropriate solution” It may only be used for the

purpose for which it has been
provided.
It must not be copied, or
passed on or disclosed to third
parties.

Created by: Alexander Kaiser/Paul Chapple

date: 01.09.2015
 2｜krones
krones Line
Beispieltext
Systems Product Management

Design process and goals

§ Economical

§ Sustainable

§ Effective

§ Flexible

The planning phase dictates 80% of your operational costs !

Line design is driven by economics „lowest costs per unit produced“

22.09.15
 3｜krones
krones Line
Beispieltext
Systems Product Management

Working Together for an Optimum Layout

KRONES
− Machinery expertise
− Whole market experience across:-
• Products
• Speeds KRONES
• Geographical areas
− Design resource

CUSTOMER
− Operational experience
• Material handling
• Logistics
CUSTOMER
• Production strategy (SKU mix, c/overs, …)
• Skill levels

Co-operation is key
22.09.15
4｜krones
krones Line
Beispieltext
Systems Product Management

“lean production” = lean line design

Lean= eliminating waste from the process

by eliminating any activity that does not add value to your product
§ Waste of space
§ Waste in accumulation to protect from poor operation
§ Waste in oversizing of machines
§ Waste in human resources

Concentration on effective Production – concentration on eliminating critical areas

“Focus on flexible Block solutions”
5｜krones
krones Line
Beispieltext
Systems Product Management

Development of economic system solutions

Lean designs “save space” ErgoBloc L

In addition:

They save operational costs Contiform Bloc  with  PET-­Asept D  Compact

- Manpower
- Energy/media
- Maintenance costs Varioline
- Investment cost

They are more “hygienic”

Contiform AseptBloc

They save packaging materials

They are more flexible

ErgoBloc D
 6｜krones
krones Line
Beispieltext
Systems Product Management

Options by Container Type

CAN

DEPAL RINSE FILL CAP PACK PALLETISE

DEPAL RINSE FILL CAP PACK PALLETISE

Standard, Fill

Ergobloc-D
Varioline bloc
22.09.15
 7｜krones
krones Line
Beispieltext
Systems Product Management

Options by Container Type

GLASS

DEPAL RINSE FILL CAP LABEL PACK PALLETISE

Standard, hot Fill

DEPAL RINSE FILL CAP LABEL PACK PALLETISE

Ergobloc-D
Varioline bloc

DEPAL RINSE FILL CAP LABEL PACK PALLETISE

Dynabloc
22.09.15
 8｜krones
krones Line
Beispieltext
Systems Product Management

Options by Container Type

PET

BLOW
DEPAL RINSE FILL CAP LABEL PACK PALLETISE
Standard, hot, aseptic fill

BLOW FILL CAP LABEL PACK PALLETISE

BF bloc Ergobloc-D
Varioline bloc
BLOW FILL CAP LABEL PACK PALLETISE
BF bloc Dynabloc
Standard

BLOW LABEL FILL CAP PACK PALLETISE

Ergobloc-L Ergobloc-D
Varioline bloc
22.09.15
9｜krones
krones Line
Beispieltext
Systems Product Management

Krones line design concepts NRB PET

Contiform Bloc
Machine setup
§ Conventional with buffer or blocked?
§ Kind of block system?
Krones offers a high variety of different solutions
ErgoBloc L

ErgoBloc L line setup

The ideal concept for your needs - space and operations
 krones
10｜ krones Beispieltext
Line Systems Product Management

Block solutions for sensitive beverages

Wet Aseptic solutions – Contiform Bloc Asept L Dry Aseptic solution – Contiform Asept Bloc
PAA bottle sterilization H2O2 Preformsterilization

Hotfill Solution – Contiform Bloc NitroHotfill

§ In Hotfill you can make lighter bottles in higher quality with higher speeds
§ In Aseptic you reduce possible contamination and increase the safety
§ In Preform sterilization Blocks you can make lighter bottles
22.09.15
 krones
11｜ krones Beispieltext
Line Systems Product Management

EXAMPLES
− WET END
• ERGOBLOC-L

− DRY END
• ERGOBLOC-D
• DYNABLOC
• VARIOLINE
22.09.15
 krones
12｜ krones Beispieltext
Line Systems Product Management

Ergobloc L – High speed line

Components of Ergobloc L

krones Module labeler

krones Modulfill krones Contiform

SJC
Neck handling throughout
CC-en31-p0104-2 10/10 CC AB

Servo joint control

Highest efficiency, lowest energy, lightest bottles
 krones
13｜ krones Beispieltext
Line Systems Product Management

Economic use of energy and media

− In the ErgoBloc L
• Energy-saving synchronous servo motors
• Brake energy recovery – for restarting ( 85% )
• No losses caused by gearwheels, friction, transmission ratio

− Through the ErgoBloc L

• Elimination of all drives in the conveyors, as well as compressed air
• No costs for conveyor lubricants
• No cleaning media for conveyors
• No energy consumption for bottle blowing

“simply less”
CC-en31-p0104-4 01/13 CC LR
 krones
14｜ krones Beispieltext
Line Systems Product Management

Advantage – high effective modular Pre Labeller

Completely dry labelling environment

Optimal control of labeling process – adjustable pressurization

CC-en31-p0104-4 01/13 CC LR

Neckhandling – no touch to the bottle

 krones
15｜ krones Beispieltext
Line Systems Product Management

Our Solution: Krones ErgoBloc L

“Elimination of everything not adding value to your product”

Conventional line 2001

Contiform Bloc line 2007

Ergo-bloc Blower-
Labeler-Filler

ErgoBloc L line 2010

CC-en31-p0104-4 01/13 CC LR

70% space saving compared

to conventional
 krones
16｜ krones Beispieltext
Line Systems Product Management

ErgoBloc L line – produce more with less

more § Higher effectiveness

less
§ Less space

§ Higher output § Less operators

§ Less energy and media

22.09.15
 krones
17｜ krones Beispieltext
Line Systems Product Management

ErgoBloc L worldwide Status August: 2015

Carbonated Soft Drinks

§ Worldwide references Still water
§ Since 2009 in production Still and carbonated water
§ Speeds up to 81.000 b/h
§ For dedicated and multi-format production

For any possible application – there is a reference

 krones
18｜ krones Beispieltext
Line Systems Product Management

Krones ErgoBloc D
DryEnd Block = shrinkpacker + (handle applicator) + palletizer

Variopac Pro Accucase Robobox Modulpal 1AD

Packer with integrated Electronic synchronized

Handle applicator Block § Lowest floor space

§ Short ways

§ High effectiveness
22.09.15
 krones
19｜ krones Beispieltext
Line Systems Product Management

Krones ErgoBloc D
Optimised layout: ErgoBloc L + D
22.09.15
 krones
20｜ krones Beispieltext
Line Systems Product Management

Krones DynaBloc
§ Blocking of labeller and packer by intelligent laned system
§ For round, square, rectangular bottles
§ For PET and glass

labeler Ultra compact laned conveying system packer

22.09.15
 krones
21｜ krones Beispieltext
Line Systems Product Management

Krones DynaBloc on one slide

§ No jams and stoppages due to crowding, nesting in Packer infeed

higher efficiency
§ Bloc speed control of packer and labeller
- no stop and go, smooth speed regulation
- less jamming, less pressure,
- higher efficiency, less damage to the bottle
§ Compact design
up to 30% less space needed

Perfect for:
§ Shaped bottles (square, rectangular)
§ Limited space available
§ For compact line design – Aseptic, Hotfill, EHF
§ Light-weight containers
CC-de31-p0104-3 06/12 CC LR
 krones
22｜ krones Beispieltext
Line Systems Product Management

Krones DynaBloc vs. conventional

up to 30% less space needed

CC-de31-p0104-3 06/12 CC LR
Meeting all expectations on todays and future flexibility

Varioline Pro
The multi flexible machine for primary and secondary packaging
The modular approach to secondary packaging
 krones
24｜ krones Beispieltext
Line Systems Product Management

´Flexible into the future

Any Way you like

Application
− Packing of loose containers in multipacks:

• Over top open

• Open carrier (open basket)
• Top carrier
• Wrap-around cartons

− Packing multipacks into secondary packaging:

• Wrap-around cartons
• RSC (regular slotted cartons)
• American box
• Plastic crates
• Displays

Just by adding modules

 krones
25｜ krones Beispieltext
Line Systems Product Management

Varioline “flexibility”
typical flexible special
Holiday pack Gift pack

Collection pack Party pack

+ combinations with film shrink application for either glass, metal or PET
22.09.15
 krones
26｜ krones Beispieltext
Line Systems Product Management

Reduced complexity – “more with less” – lean manufacturing

Box shop

Floor space access effectiveness manpower

22.09.15
 krones
27｜ krones Beispieltext
Line Systems Product Management

LEAN LINE DESIGN SUMMARY

− Design Partnership and Lean
Philosophy delivers

• Smaller footprint
• Reduced losses
• World Class efficiencies
• Optimum Flexibility
• Easier operation & service
• Lower costs
• Longer lifetime
22.09.15
 krones
28｜ krones Beispieltext
Line Systems Product Management

Krones filling and packaging technology – “running for decades”

More than 300 turnkey lines

for beverages supplied per year.
22.09.15
 This document is property of

Thank You ! the krones Group and

contains confidential
information.
It may only be used for the
purpose for which it has been
provided.
It must not be copied, or
passed on or disclosed to third
parties.

Created by: Alexander Kaiser

date: 01.04.2015