Success Story: Manufacturing, None

KHS Maschinen

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Dortmund, Germany

KHS is a market leader in the deployment of Aseptic Cold Filling (ACF) applications for the beverage market. With the ACF process is that KHS completely eliminated the need for preservatives, thus improving product quality. KHS standardized on GENESIS to control its applications and machines and to visualize the entire ACF process.

Needs

  • Must support FDA 21 CFR Part 11 requirements.
  • Be able to switch language at runtime.
  • Have an intuitive configuration environment, and allow rapid development.

Results

  • Audit trails and multi-level password protection are built into the security server. All operator interaction (who, where, when and what) is documented and stored in a database.
  • Graphic symbols, as well as trend and alarm applications, can be created once and reused for multiple languages. It can even switch languages at run-time.
  • GraphWorX™'s symbol library provides the application engineers with often-used symbols, and allows users to save custom symbols with all dynamic and language-specific connections for later use.
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About KHS Maschinen

KHS, with headquarters in Dortmund, Germany, is a market leader in the deployment of ACF (Aseptic Cold Filling) applications for the beverage market. KHS offers the highest level of competence as an international fullservice provider in planning, deploying and maintaining filling and packaging applications for the food and beverage industries. In 2003, KHS generated revenue of 700 million Euros with 3,200 employees around the world. Eckes-Granini Deutschland GmbH is a market leader in Europe in the fruit juice market. At its facilities in Bad Fallingbostel, Germany, Eckes-Granini successfully deployed an innovative aseptic cold filling application by KHS. Specialty fruit juices are microbiologically sensitive and perishable when exposed. The ACF (Aseptic Cold Filling) process allows for fruit juices to be filled into PET bottles at a temperature of only 68 Deg F (20°C). The main advantage with the ACF process is that KHS completely eliminated the need for preservatives, thus improving product quality.
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KHS Parameter Display Screen KHS Parameter Display Screen

ICONICS Software Deployed

KHS standardized on GENESIS to control its applications and machines and to visualize the entire ACF process. The GENESIS Software Suite is able to meet KHS’ sophisticated needs for scalability, graphic capabilities and modularity for machine control and visualization. GENESIS communicates via OPC and Profibus to a Siemens S7 PLC and I/O running on Microsoft Windows. GENESIS, as a modular suite of products, allows KHS to use only the components they need. It is easy to add modules, as the complexity and requirements of the process change. All ICONICS client software modules are based on OPC technology, which makes it easy to communicate and interact with other automation hardware and software products.
KHS Parameter Display Screen KHS Parameter Display Screen

Project Summary

Process Display at KHS Maschinen Process Display at KHS Maschinen
GENESIS also offers an excellent international language switching technology. Graphic symbols, as well as trend and alarm applications, can be created once and reused all over the world, resulting in tremendous savings in areas of applications engineering and support.
Process Display at KHS Maschinen Process Display at KHS Maschinen
Production Management Screen Production Management Screen

Key Features

Another major advantage of GENESIS is its integration in today’s IT environments. Using GenBroker™, OPC and SOAP/XML communications technology makes it easy to connect and visualize processes in existing IT structures. Also, accessing enterprise-wide databases is essential when analyzing historical production and business data.

KHS appreciates the intuitive configuration environment of GENESIS. GraphWorX allows for the easy creation of animated 3D graphics to visualize process applications. The Symbol Library provides the application engineers with often-used symbols, and also allows users to save custom symbols with all dynamic and languagespecific connections for later use.

The ICONICS Security Server provides a built-in security architecture that supports FDA 21 CFR Part 11 requirements. Audit trails and multi-level password protection are built into the Security Server. Therefore, all operator interaction (who, where, when and what) is documented and stored in a database.
Production Management Screen Production Management Screen
Aseptic Cold Filling at a KHS Maschinen Beverage Industry Customer Aseptic Cold Filling at a KHS Maschinen Beverage Industry Customer

Conclusion

KHS’ high expectations in its ACF application and GENESIS software have been met. Both KHS and ICONICS provided innovative solutions in their respective fields, resulting in a major contribution to the quality of Eckes-Granini fruit juice products.
Aseptic Cold Filling at a KHS Maschinen Beverage Industry Customer Aseptic Cold Filling at a KHS Maschinen Beverage Industry Customer