Measurable efficiency: enviro under audit in Flensburg

Particular attention was paid to the Lavasonic HI, a newly developed cleaning machine for returnable bottles. It was specially configured to meet high hygiene requirements while consuming the least possible energy, water and chemicals.  for returnable bottles. It was specially configured to meet high hygiene requirements while consuming the least possible energy, water and chemicals. 

Saving resources when washing bottles

The machine reduces the cleaning times of bottles by up to 40 percent compared with its predecessor, the Lavatec. At the same time, the energy required is up to 30 percent lower and freshwater consumption is down by as much as 20 percent. This is made possible by the combined use of ultrasound in the pre-treatment phase and a high-intensity module which specifically removes the residue (hence the suffix “HI”). Ultrasound detaches labels and dirt faster while also reducing the ingress of ink and dirt particles into the caustic solution, which means less chemicals are needed. Another critical optimisation is that the bottles are locked in place during the cleaning process, so their freedom of movement is restricted. This allows more intensive cleaning in a shorter treatment time while simultaneously reducing the mechanical load on the bottles. The latter feature is particularly beneficial with lightweight returnable bottles, as it means wastage can be significantly lowered.

Predicting consumption exactly

A digital solution was also introduced in the audit: A forecast tool that calculates the utility requirements and consumption data of the Lavasonic HI and other cleaning machines. Put simply, the web-based application shows in advance what quantities of resources a machine will need for its different production programmes. Thanks to the modular design and standardised interfaces, data can be exchanged automatically between different systems. Not only does this simplify day-to-day work, it also lays the foundation for seamless integration into future process landscapes. Another advantage is the high simulation accuracy: As well as water and heat consumption, it is now also possible to take electrical energy consumption and other line components into consideration. In addition, different machine configurations can be compared directly with each other in a single view. This quickly reveals which variant is the best choice for the particular application. 

The figures are calculated on the basis of a compiled MATLAB model which only uses the functions that are relevant for the calculation. This makes it possible to simulate different production programmes and operating states both quickly and realistically. 

Smooth container flow 

Another system that was examined in Flensburg was the LinaFlex eSync. The tunnel pasteuriser extends the shelf life of beverage products by heating and then cooling them within strict parameters. To achieve this, the already filled and sealed containers are led through a number of temperature zones.

Smooth container flow 

Another system that was examined in Flensburg was the LinaFlex eSync. The tunnel pasteuriser extends the shelf life of beverage products by heating and then cooling them within strict parameters. To achieve this, the already filled and sealed containers are led through a number of temperature zones. 

The LinaFlex eSync fundamentally reorganises the pasteurisation process – and does so with a consistently single-lane conveyor concept. This eliminates the need for classic mass flow conveyors and external buffer areas, as these are integrated directly into the machine. That in turn reduces the energy required for the whole line by around 25 percent, and in the wet section by as much as 40 percent. What is more, the pasteuriser adapts dynamically to the filler output, which brings more flexibility and efficiency into the line. An intelligent controller combined with a heat recovery system slashes energy consumption while at the same time ensuring consistent product quality without micro stops. The result is a more compact line with a lower energy demand and more stable processes. Customers wanting to get the maximum energy out of their products can also install a heat pump and thereby reduce their carbon footprint still further. 

Conclusion and outlook  

The audit confirmed one thing above all: enviro is a central lever for measurably improving energy and media efficiency in Krones products. The management system is constantly being refined and optimised. TÜV SÜD gave a positive report on the latest adjustments with regard to cleaning and product treatment technology. For Krones, enviro provides an overarching framework for evaluating, documenting and comparing technical improvements in a structured way and explaining them to customers in terms they will understand.

Looking forward, the conditions are very good on the whole: TÜV SÜD gave positive feedback on this audit. The next major recertification audit is due as early as next year, and Krones is well prepared for it. The enviro programme is our tangible contribution to the implementation of sustainable technologies and aims to reduce both emissions and the consumption of energy and media. At the same time, the issue of cost-effectiveness also plays a central role: Not only does the lower use of resources allow costs to be reduced, it also strengthens resilience to rising energy prices and regulatory requirements. Krones’s efforts to sell more enviro machines is a key contribution to our sustainability goals and will be continued. The enviro management system is to be rolled out in stages to other subsidiaries as part of the 2027 recertification audit. The development of enviro is continuing at pace, underpinned by close cooperation between the user departments and the clear support of the management.