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FILTECH

drink Technology + Marketing · March 2011

FILTECH 2011

and techniques concerning important aspects of separation technology. A high calibre Scientific Committee assists in the preparation of the congress directed by the two chairpersons Prof. Dr. Eberhard Schmidt from the University of Wuppertal and Dr. Harald Anlauf from the Karlsruhe Institute of Technology (KIT). In addition to the congress one day prior to FILTECH 2011 on Monday 21st March 2011 two 1-day short courses will be held. Congress language will be English.

The story of growth continues and FILTECH has expanded its exhibition space from three to now five exhibition halls, welcoming exhibitors and visitors from all over the globe. FILTECH 2011 will feature 220 innovative companies and market leaders from the world-wide filtration and separation industry, including both a strong line-up of returning companies as well as an impressive collection of first-time ex-hibitors. With more than 50 % foreign visitors FILTECH will have a distinctly international flare and is a unique platform for learning about trends, gathering information, and generating business. To date, more than 80 % of the exhibition space is sold and the number keeps growing.

For years now FILTECH has registered substantial growth (2009: 42 % more Exhibitors / 25,5 % more visitors) and enables the event to reaffirm its claim as the leading meeting place for mechanical separation systems and, to an increasing extent, for associated measurement and analysis systems.� Key�No.�75405

Explore�the�Future�of�Filtration�and�Separation

The international congress provides a platform for academia and all those keen to learn about latest research, global developments, and new approaches, and will feature 180 technical papers by experts from all over the globe. On 7,400 square metres of exhibition space, companies will present their innovations to an international audience of buyers, sellers, users, designers, R & D experts, and the academic world.

With its extensive programme the international congress, designed as a four-phase congress, will give a survey about latest research. During the three days of congress the presentations will offer a representative cross section of current research findings, global developments, and new approaches to solving problems with respect to the methods for the classic mechanical separation of particles from liquids, the gas cleaning and membrane filtration methods. This ranges from mineral dressing to biotechnology, pharmaceu-ticals, and chemicals right up to envi- ronmental technology and water puri-fication. In addition to the current findings of research on the basics for describing and simulating separation processes, new instrumental solutions, and methods will be presented, including the description of filter testing, particle measurement, methods of membrane characterisation, and other peripheral field-proven components.

Special highlights are a plenary and six survey lectures in which internationally renowned experts give a comprehensive overview of state of the art knowledge

Ceramic�Membranes

atech�innovations�GmbH,��Hall�5,�Stand�S7-6

Operators of membrane filtration plants require long service lives, top quality filtration and investment costs which are as low as possible and pay off within a short time. These are the requirements that atech innovations gmbh uses as orientation when developing its products. Nothing else but high-purity material is used to produce these membranes, ensuring long service lives as well as permeate quality. An investment that pays.

atech's product development aims at making the construction of filtration plants easier still: for example by raising the number of membrane channels to as many as 85 or by increasing the length of membrane elements to as much as 1.5 meters. This results in lower investment costs per square meter of filtering surface and lower specific cost for pressure vessels.

Now, a 1 kD membrane is available as well for applications which require a very small cut off size, such as decolorization of juices or other liquid foods.

atech innovovations gmbh is not only focussed on the issue of cost effectiveness but also on the specific application of its products such as tank bottom beer, wine, juices, milk proteins or gelatine.

atech innovations gmbh, based in Gladbeck, is a developer and producer of high-quality ceramic membranes for a wide range of industrial applications. Highly qualified personnel (chemists, engineers for process and food tech-nology) work for customer from various industries all over the world.� Key�No.�75406

With�FILTECH�2011�taking�place� from�22�-�24�March�2011,�

the� City� of� Wiesbaden,� Germany,� will� turn� into� a� meeting�

place�for�all�those�involved�with�filtration�and�separation�and�

adjacent�sectors.�More�than�220�exhibitors�will�feature�the�

latest� innovations� and� up-to-date� filtration� and� separation�

technology�on�7,400�m2�exhibition�space.

21

FILTECHFILTECH 2011

drink Technology + Marketing · March 2011

Two business units of the technical weaving mill GKD – Gebr. Kufferath AG are presenting their product innovations at the trade fair for filtration and separation technologies, FILTECH 2011, in Wiesbaden. SolidWEAVE, developer and manufacturer of high-precision technical mesh systems and complex filter media is presenting for the first time its NeverLeak technology.

Expansion�of�the�NeverLeaktechnology�In the USA the NeverLeak technology has been a leader for many years now in, among others, the field of beer filtration. Now the system has also been further developed and improved for conventional plate-type and horizontal plate filters. The secure structure of the filter frame with filter media made from especially stable PZ meshes ensures leak-free filter sealing up to the edge area. The novel and robust frame construction allows the production of the plates to be tailored to individual customers and markedly optimized

Sefar GmbH is the leading manufacturer of monofilament precision fabrics for customer-tailored solutions in industrial processes, filter components, screen printing and architectural applications.The company provides filter solutions for the main types of equipment used in the process industries, based on fabrics that have been developed by Sefar to meet the needs of the customers. It has always been the aim to minimize the customers' overall process costs by reducing waste and energy require- ments by maximizing the service life of all products.

Sefar stands for:• Customized solutions that meet the

industry's most stringent require-ments (e. g. high temperatures, chem-ical resistance and long life-time)

Herrmann Ultraschall offers continuous ultrasonic technology for the bonding, laminating, embossing, perforating, sew- ing and cutting of nonwoven, foils, paper and filter materials at high speeds and maximum precision.

The ultrasonic welding process is ideally suited to the welding of coated carton packaging. The use of carton packaging for milk, beverages, and other food products requires a very high degree of barrier properties and tightness to consistently maintain the quality of the packaged goods. Herrmann ultrasonic sealing systems are specifically adapted to the requirements of aseptic filling.� Key�No.�75409

with regard to costs. The new frames are available as of now in various filter designs. If required, they can also be refitted with a new mesh without any problem and so can be used several times.

• Integrated production: all crucial steps from yarn production and weaving to fabrication of ready-to-use filters

• High quality and traceability• Complete fabric range• Bacteriological Filters, Filter Textiles,

Belt Filters, Filter Tubes, Candle Fil-ters, Fuel Filter Media, Centrifuges, Medical Filters, Coalescer Media, Meshes, Synthetic, Coolant Filters, Sieves, Filter Bags, Strainers, Filter Centrifuges, Technical Textiles, Filter Cloth, Vacuum Filters, Filter Elements, Waste Water Filters, Filter Fabrics, Wire/Wowens, Filter Media, Wirecloth Filters, Filter Media for Liquids

� Key�No.�75408

Worldwide�unique�simulation�of�multi-layer�meshes�As part of the presentation series "Filter media - Modelling, Simulation, Design," Dipl.-Eng. Markus Knefel, an engineer at GKD, is showcasing on 22nd March the new possibilities in the simulation of multi-layer technical meshes. The software tool WeaveGeo that was further developed three years ago by the company allows for the first time the generation and subsequent simulation of filter tasks in a way that allows very precise statements to be made. As the result of the expansion of the simulation technology, the company can now simulate and virtually optimize under customer-specific conditions as well the structure and behaviour even of highly complex multi-layer meshes under process conditions. The realistic depiction and prediction of the behaviour of the mesh constructions have shown themselves to be highly reliable in a direct comparison with laboratory measurements.� Key�No.�75407

Leading�Filter�Solutions�On�The�Basis�of�Technical�Meshes

�GKD�–�Gebr.�Kufferath�AG,�Hall�4,�Stand�L4

Monofilament�Precision�Fabrics

SEFAR�GmbH,�Hall�1,�Stand�C9

Ultrasonic�Welding�&�Sealing�Systems

Herrmann�Ultraschalltechnik��GmbH�&�Co.�KG�GmbH,�Hall�1,�Stand�E11

The Maxflow compact filter system as a twin-

system with an additional filter head.

22

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drink Technology + Marketing · March 2011

sciously on tried-and-tested, high-quality technical components which – and this is of the utmost importance – are excellently maintained by KHS' O + H Services. This service includes supply-ing us with original spare parts and carrying out regular maintenance, and also permanently adapting our technical setups to cope with the latest requirements."

Oldest�Roman�spring�in�GermanyThe Romans first discovered the bubbling waters of the Tönisstein spring over 2,000 years ago, yet centuries later it lay buried and forgotten. The great-grandfather of today's managing partners graduate engineer Tilman Kerstiens and graduate economist Klaus Körner procured the ancient Roman source in 1891, primarily because as a chemist he intended to extract carbon dioxide from it.

It was not long before the carbon dioxide works and mineral water plant were operating side by side. In the 1960s,

business concentrated solely on mineral water as the demand for bottled water rose rapidly during this period, making the undertaking a profitable prospect.

Profitability�before�quantity"Keeping our bottling plant running at a profit is still our top concern," explains Kerstiens. "In a day and age when mineral water is more or less given away by discounters, this isn’t that easy."

Despite the unfavorable market, Tönis-steiner Privatbrunnen still aims to market its mineral water products as brand-name goods. With the Tönissteiner brand in the top price segment, Eifel-Quelle is placed in the top middle price bracket. One strategy that has helped to keep pricing clear is the fact that the bottling plant is strongly geared towards specialized wholesalers. At Tönissteiner, 97.5 % of sales go to beverage wholesalers, with just 2.5 % being delivered direct to food retailers. Supplying discounters is not an issue – neither now nor in the future.

Rhineland-Palatinate, Brohl-Lützing: the official site of the oldest known Roman spring in Germany. It is also the site of Tönissteiner Privatbrunnen, a mineral water bottling plant. Now in its fourth generation of family ownership, Tönis- steiner does not just supply its con-sumers with a product the Romans once savored but also with an extremely palatable mineral water that has won several awards. The company also stands for clear brand leadership, has a strong presence and plenty of competence in the hospitality trade, and is also a pioneer in many different fields. Tilman Kerstiens, managing partner of Tönissteiner Privatbrunnen, says, "To exaggerate, we would say we see ourselves as a service provider with a sideline in mineral water. And this includes customers and their demand for top quality across the board being the chief focus of our business." This aspect also applies to the filling and packaging technology used in Brohl-Lützing. Kerstiens explains, "With O + H systems we are relying quite con-

Focusing�on�the�BrandTönissteiner�Privatbrunnen�believes�in�quality�right�across�the�board

by MICHAEL SCHMIDT

The O + H line, commissioned in 1994, profits from regular maintenance by KHS Services and top care

from the team at Tönissteiner. It features an integrated double-end bottle washer …

… an O + H conveyors …

Photos: KHS GmbH

drink Technology + Marketing · March 2011

absolutely clear: Must and wine clarification with process technology from GEA Westfalia Separator Group enhances yield with optimal product quality. The self-cleaning, high-performance GSC 250 clarifier was specially developed for this objective. Its Westfalia Separator® hydry® technology increases productivity by a maximum of solids concentra-tion, at high throughput. This means greater yield and higher earnings, day by day.

Hydrohermetic feed eliminates negative shear forces. Absorption of oxygen is reliably prevented by hydrohermetic discharge. Compared to other processes, the separated must can be more effectively fermented, stabilized and filtered.

The great separating efficiency pays off, litre for litre: Liquids to Value for convincing return on investment.

Your direct route to 24 / 7 service: www.westfalia-separator.com / service

BE-2

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001

GEA Mechanical Equipment

GEA Westfalia Separator GroupWerner-Habig-Straße 1 · 59302 Oelde (Germany)Phone +49 2522 77-0 · Fax +49 2522 77-2089www.westfalia-separator.com

More productive wine and must clarification

Don‘t Worry – He‘s just Crazy about the Payback

Liquids to Value

Award-winning,�quality�mineral�waterAlthough visually appealing restaurant bottle designs do much to nurture their popularity among clients in the catering trade, this alone is not enough to ensure the levels of success Tönissteiner has reached, for example. What is of the greatest importance to a restaurant is that the mineral water they serve harmonizes well with their food and wine. Mineral water from Tönissteiner is distinguish-ed by its high m a g n e s i u m and calcium content, low sodium levels, and complete lack of nitrat- es and nitrit-es. The fact that the min-eral water is also agreeable and very palatable is confirmed by numerous awards. On a national level, Tönissteiner mineral water has repeatedly won gold medals for its Classic, Medium, and Naturelle mineral water from the Deutsche Landwirtschafts-Gesellschaft or German Agricultural Society (DLG). Internationally, in the last three years the company has received the top three stars award for all three water styles from the International Taste Quality Institute in Brussels, Belgium. This meant that in addition to various other certificates and medals in 2010 Tönissteiner was able to receive the Crystal Award for winning three times in a row. In 2010 – as in the two previous years – the International Institute for Quality Selections (Monde Selection) also presented Tönissteiner with three gold medals for its Classic, Medium, and Naturelle products, two of which were Grand Gold Awards. "We are delighted with all these prizes," enthuses Kerstiens, "especially as various ex-perts, master chefs, and nutritionists confirmed at all of the blind tasting sessions that our Tönissteiner mineral water is of absolutely top quality."

Also�a�brand�name�in�BelgiumThis top quality is not only popular in Germany. Looking at the export figures for Tönissteiner Privatbrunnen, the Tönissteiner brand is the biggest German export brand in the mineral water

business. This is partly thanks to the ties to Belgium that have become established over the years and to the family business factor coming into play. Their general importer in Belgium is also a family-run firm and now in its third generation; it has been distributing Tönissteiner brand products on the Belgian market for exactly 51 years. Kerstiens claims, "We share identical values, such as trust, flexibility, speed, and short distances. We

complement each other very well and this explains our mutual success."

This mutual success now makes up a good third of

the bottling plant's sales. In 2009, Tönissteiner Privatbrunnen's total sales figure was about 130 million filled units. An increase of over four percent is expected for 2010.

Of interest with regard to the company's export activities on the Belgian market is the fact that despite the close proximity of the two countries, Belgian consumers show very different preferences. This particularly applies to soft drinks. The apple spritzer Tönissteiner Apple Mix, for example, has a low turnover in Belgium, whereas in Germany it is marketed throughout the land with much success. The Früchtekorb nectar brand, now superseded in Germany by interesting mixed fruit innovations, is selling well in Belgium, on the other hand. Another example are the reduced-calorie soft drinks in Tönissteiner’s Fit Range, not in particularly great demand in Germany but all the more so in Belgium. "As far as our range of soft drinks is concerned," says Kerstiens, "we focus entirely on the wishes of our German and Belgian customers. Not least for this reason do we market soft drinks and fruit beverages in 22 different flavors."

Pioneer�of�the�apple�spritzerAll told, soft drinks account for about 30 % of Tönissteiner's sales volume. As well as the classic soda pops, the Apple Mix spritzer is also especially successful.

Key�No.�74809

"Our�customers�and�their�demand�for�topquality�are�the�chief�focus�of�our�business."�

TILMAN KERSTIENS, Managing Partner of Tönissteiner Privatbrunnen

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drink Technology + Marketing · March 2011

Approximately one third of soft drink sales is attributable to the latter; this is in such demand because when the company launched Apple Mix on the German market in 1994, as only the second mineral water bottling plant in Germany to do so it was a true pioneer – and ahead of the trend for apple spritzer. Kerstiens proclaims, "Among other things, thanks to this market advantage we were able to achieve unprecedented success with Apple Mix before the trend really took off."

The more recent products to have established themselves in the soft drink range are the mineral water plus fruit juice creations Waldfrucht (wild berry) and Exotic, presented in 2009 as being particularly "light and fruity". And they, too, are well received by consumers. Waldfrucht especially is a big hit with the kids, meaning that the product is not only filled in PET containers but also in the exclusive restaurant bottle.

Medium�beats�ClassicIf we study the sales figures for mineral water, which makes up 70 % of total sales, distribution among the various types of water is as follows (split into household and hospitality trade consumption): 54 % for Medium in the household size and 10 % in the restaurant sector; 43 % for Classic drunk at home and 70 % in restaurants and bars; 20 % for Naturelle

in the hospitality trade and just three percent in private consumption.

An�entire�portfolio�of�glass�bottlesTönissteiner Privatbrunnen fills its soft drinks and mineral water in no less than ten different types of refillable container. The various types of glass bottle include the 0.25-liter and 0.75-liter exclusive restaurant bottle, the 0.7-liter/0.75-liter

GDB standard German mineral water bottle, the 0.25-liter Vichy bottle, and a special green glass 0.75-liter bottle destined for the Belgian market. The refillable PET bottles used include the 0.75-liter, 1.0-liter, and 1.5-liter sizes.

Concentrating on the number of fillings alone, each year 74 % of all beverages are bottled in glass, this percentage being

… an O + H filling system … Ingo Dohmen, Production Manager: "Over the

years we have been given excellent support."

… and O + H dosing and blending equipment.

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Processing

drink Technology + Marketing · March 2011

largely founded on the high number of 0.25-liter exclusive restaurant bottles processed.

K42�and�K54�operating�reliably�Considering how vast an importance the 0.25-liter single-serve restaurant bottle holds for Tönissteiner Privatbrunnen, the above figures partly explain why the two glass lines have been named K42 and K54. The number after the K indicates in thousands the bottling capacity of the line obtained per hour for the 0.25-liter single-serve bottle. The letter K (for Kettenbetrieb or chain operation), however, goes way back to the days when the mineral water sector showed great enthusiasm for the then new-fangled method of conveying bottle pockets in bottle washing machines by chain drive. Although the names of the lines lean heavily towards the exclusive 0.25-liter restaurant bottle, the talents of the two systems go much further. The K42, for instance, processes the full spectrum of glass Tönissteiner bottles, including the Belgian glass bottle types, and the K54 handles all but three of the plant’s varieties of glass container.

The�service�is�rightAs pleased as Kerstiens still is with the lines commissioned in 1994 and 1998, in the year 2000 he felt he was at a loss. At least he did until KHS took on the service and spare parts units of Crown Simplimatic Ortmann + Herbst Maschinen- und Anlagenbau GmbH who had gone bankrupt. Before this was the case, he was worried about where he would get spare parts from in the future – and who would now help him with the maintenance and service of his machines? "In retrospect I can say that everything was always perfect for us thanks to the fast integration of O + H Services by KHS," says a relieved Kerstiens, "as it still is. Over the years we have always received our spare parts reliably and on time."

Coping�with�new�eventualitiesThe O + H lines are still giving the best filling and packaging quality, partly because the various measures undertaken by Tönissteiner are always rooted in their demand for the highest quality. The lines, operating every

weekday in two shifts, are thus subject to regular overhauls by KHS service engineers. At the same time the lines have been adapted to cope with new eventualities. One of these was in the field of control technology. The filling area is now exclusively equipped with new S7 control units in place of the old S5s. A touch-screen monitor has also been integrated into the system. Another example is the dosing and blending equipment, where new measurement technology has been installed. "We are constantly modernizing and optimizing

our setup," states Kerstiens. "For example, our next project is to tackle new things in the packaging area every time it’s overhauled, including conversions."

Always��available�–�even�in�emergenciesKerstiens feels he receives excellent support – even in emergencies. The 24- hour hotline was recently used by Tönissteiner. "We desperately needed new seals for our pressing cylinders in the filling system," explains Kerstiens. "I called the hotline on Friday evening. Thanks to their speedy assistance, the seals arrived at the plant the very next

day. We were able to continue production with only a brief interruption. That's just what I imagine fast help should be like."

In the future Kerstiens will continue to bank on his existing O + H technology. Line K42 in particular, whose line efficiency is still 85 %, is something he cannot do without. Says Kerstiens, "Even in the distant future we're not planning to invest in a replacement line. However, we could imagine gradually integrating new machines in our existing lines."

The�future�has�room�for�improvementIn other areas, too, Tönissteiner Privatbrunnen seems to have planned for the future. Their focus remains firmly fixed on one thing however: giving the consumer quality – and plenty of it at all times. This includes the continued success of the Tönissteiner brand. The link of brand name and product quality is excellently communicated to the public in the mineral water bottling plant's advertising campaigns. Tönissteiner's rain of medals is praised in the region's daily newspapers, for example. Slogans such as "Naturally selected" and "Annually prized" help. Kerstiens is convinced that the private company will continue to profit from the trust and thus great attention marketing agents and consumers place in and show the family business. All these aspects together form the basis for targeted further growth – a growth that will continue at Tönissteiner as long as the return on investment is right. Kerstiens remarks, "Returns come before quantity. Despite this strict prerequisite we have set ourselves, we reckon on future success. At the moment we’re among the top 20 of German mineral water brand suppliers and are one of the top 3 German mineral water brand suppliers in the hospitality sector. We see room for improvement here. Also," he adds with a grin – and to offer a rough translation of the company's chief marketing slogan – "because Tönissteiner is more than just a drop in the ocean – and has been for over 2,000 years". Key�No.�75396

The Author Michael Schmidt works for Service O + H at KHS GmbH in Hamburg, Germany.

www.sick-solutions-tour.comwww.sick-solutions-tour.com

Details on the sensor solution at:Details on the sensor solution at:

Tour Stop No. 41: Beverage, Food & Luxuries

How can you save 12.5 million labels per year in tea bagproduction?

11270_Textfeldanzeigen_alle_60x110_DE_GB.indd 37 04.03.11 14:58

Key�No.�75355