New SmartCan filler-seamer block by KHS and Ferrum

Aiming for flexibility, efficiency, and operation

SmartCan filler-seamer block by KHS and Ferrum. Photo KHS

The KHS Group has launched its SmartCan filler-seamer block developed together with Swiss engineering company Ferrum. The hygienic design of the compact system is convincing with its perfect product quality and safety, and gives operators clear benefits when it comes to flexibility, efficiency, and operation, the company said.

Whereas in the past chiefly beer and carbonated soft drinks were filled into cans, for some time now there has been an ever stronger trend for canned more sensitive products such as iced tea, plant-based drinks, juices, smoothies, near-water products or alcohol-free beers and mixed beer beverages. This development means that beverage fillers’ hygiene requirements are also becoming more discerning – among them are systems supplier KHS and specialists such as Ferrum. With their SmartCan filler-seamer block, for the first time, the two companies have now effected a seamless union of their respective machines that boasts an optimized hygiene concept and jointly provides more flexibility, greater efficiency, and simple operation.

Wealth of innovation

With regard to its successful and popular can fillers, KHS has many new features to offer, especially in the medium and high capacities, which have already proved themselves on its modular filling platforms for PET and glass bottles. Instead of using conventional cams and rollers, the bell guides are now pneumatic, for instance. This makes for a smooth filler silhouette that is quicker and easier to clean. A similar effect is created by the use of PTFE as a sealing material that can be cleaned easily and very effectively. Because of PTFE, the bell expansion joints no longer need to be lubricated with water, resulting in improved hygiene and lower consumption of cleaning media. Furthermore, using PTFE more or less completely rules out flavor carryover from one product to another. This gives beverage producers more flexibility in their production planning.

In the development of the new block, KHS paid particular attention to the clean room in the filler section, equipping it with raised jacket plates along one side. On the other, the housing features a much smaller product room around the filler carousel, enclosing it in a ring like a donut. This reduces the volume of the hygiene zone by about 40% and ensures an optimum, targeted flow of sterile air through the sensitive area.

Multiple optimizations

Other than you might expect with this much smaller design, operators nevertheless have plenty of room to work, states Manfred Härtel, filling product manager for KHS. “We don’t use any tight-fitting cladding that’s difficult to access. Each section of the filler that may call for manual intervention during maintenance, overhauls, or format changeovers can be easily reached.” The aim is to cut the amount of manipulation by hand down to a minimum to create optimum hygienic conditions. Nowadays you usually work with closed paneling where filter fans supply sterile air to the sensitive filling section and protect the open cans from ‘impure’ shop air, he explains. As many functions as possible have also been automated – from clearly defined cleaning cycles and automatic CIP caps to the aforementioned bell guides.

For the first time on the further developed filler, the belt and feed screw drives are separate to enable different forms of lubrication. This allows the contact pressure on the empty, often very thin and – without lids – rather unstable aluminum cans to be regulated individually and especially gently, minimizing the axial and radial load. The improved can flow gate has a similar effect; this prevents individual containers from being damaged or downed by sudden stops.

Finally, the hygiene of the wiring on the new filler platform has also been optimized, Härtel adds. “The power cables that are led out from each servo drive to the control cabinet have now been encased in closed pipes. This naturally further enhances the excellent hygiene of the entire block.”

Great benefits

The Ferrum seamer was redeveloped especially for the joint block system. The further developments made here also serve to avoid possible soiling. “The greatest step taken here was to implement the product room in a closed, hygienic, stainless-steel design,” says Marc Zubler, head of Sales and Product Management at Ferrum Packaging. “With this new concept, we were able to make the product room much smaller. This shortens the cleaning time and reduces the amount of cleaning media needed. Merging the filler and seamer to form a single unit also gives us a smaller machine footprint.” The new sloped plate is also of an advantage as it facilitates the runoff of liquids. The same applies to the new can transfer unit based on a horizontal toothed gear setup instead of the previous stopped chain. This ensures that no splashing water enters the open can. With its open design and lack of guides, the construction is easier to clean and thus also convincing when it comes to hygiene.

Flexible block system

Zubler considers another plus, the flexibility of the block system, for which Ferrum also developed a number of new features and automated several functions. Examples include recipe-specific height adjustment, seaming cam adjustment, and a quick-change system for format parts that are much easier to handle and thus shorten conversion times by up to 30%. Moreover, all machine settings can be made from the floor, and, as with the filler, large doors that can be opened ergonomically give optimum access.

Cans with a diameter of between 50 and 73 millimeters and a height of 88 to 200 millimeters are processed. “In view of the expected further reductions in the material through lightweighting, we’ve increased the number of stations from twelve to 14 to reduce the load on the cans so that these can be seamed without damage,” Zubler stresses. “The filler/seamer block we’re presenting at drinktec for the very first time has a maximum output of 108,000 cans per hour. In the future, we’re planning on expanding our concept to cover higher capacity ranges.”

A further major boon of the SmartCan by KHS/Ferrum is its simple operation on the KHS ClearLine HMI that constitutes a joint intuitive user interface for both the filler and seamer for the first time. Both units can be connected up to the KHS ReDiS remote diagnostics system as an option through a shared link that in an emergency grants fast access to the machines, enabling faults to be analyzed and remedied without an engineer having to be physically present.

The impact, resilience, and growth of responsible packaging in a wide region are daily chronicled by Packaging South Asia.

A multi-channel B2B publication and digital platform such as Packaging South Asia is always aware of the prospect of new beginnings and renewal. Its 16-year-old print monthly, based in New Delhi, India has demonstrated its commitment to progress and growth. The Indian and Asian packaging industries have shown resilience in the face of ongoing challenges over the past three years.

As we present our publishing plan for 2023, India’s real GDP growth for the financial year ending 31 March 2023 will reach 6.3%. Packaging industry growth has exceeded GDP growth even when allowing for inflation in the past three years.

The capacity for flexible film manufacturing in India increased by 33% over the past three years. With orders in place, we expect another 33% capacity addition from 2023 to 2025. Capacities in monocartons, corrugation, aseptic liquid packaging, and labels have grown similarly. The numbers are positive for most of the economies in the region – our platform increasingly reaches and influences these.

Even given the disruptions of supply chains, raw material prices, and the challenge of responsible and sustainable packaging, packaging in all its creative forms and purposes has significant headroom to grow in India and Asia. Our context and coverage engulf the entire packaging supply chain – from concept to shelf and further – to waste collection and recycling. We target brand owners, product managers, raw material suppliers, packaging designers and converters, and recyclers.

In an admittedly fragmented and textured terrain, this is the right time to plan your participation and marketing support communication – in our impactful and highly targeted business platform. Tell us what you need. Speak and write to our editorial and advertising teams! For advertisement , for editorial and for subscriptions

– Naresh Khanna

Subscribe Now


Please enter your comment!
Please enter your name here