KHS pioneers low-loss beverage filling with advanced CFD simulations

GERMANY – KHS, a leader in beverage filling technology, has developed an innovative way to reduce product waste and improve cleanliness in high-speed bottling lines at its Bad Kreuznach facility.

By using advanced computer simulations, known as computational fluid dynamics (CFD), the company has tackled product loss and hygiene issues caused by liquid sloshing in high-speed bottle filling.

Through analyzing bottle and machine parameters, KHS has optimized designs to ensure safer, cleaner, and more efficient operations at its Bad Kreuznach facility in Germany.

Dominik Weirich, a KHS development engineer, emphasized the importance of these simulations, stating, “Ever higher filling outputs mean we must account for liquid sloshing when designing machines.”

The CFD calculations, totaling around 850 to date, focus on two parameter groups. 

Geometric factors, like bottle shape, fill height, and neck diameter, are analyzed in collaboration with Bottles & Shapes experts, especially for new projects or lightweight container designs.

Machine parameters, including capacity, pitch, and star diameters, allow for simpler adjustments, while container adaptations require iterative processes. 

In most cases, high-speed filling, with up to 90,000 bottles per hour, generates centrifugal forces that cause beverages to spill, particularly during transitions from transfer stars to closure systems. 

Even minor spillage accumulates significantly, increasing cleaning demands and reducing production time due to contamination risks, such as mold from sugary residues on bottle necks and closures.

Weirich noted that larger liquid surfaces and higher fill levels near bottle mouths increase sloshing risks. 

These simulations inform both machine engineering and customer offers, ensuring tailored solutions. 

Earlier this year, KHS achieved its first-ever platinum rating from EcoVadis, placing it among the top 1% of companies worldwide for sustainability performance.

EcoVadis, a globally recognized platform assessing over 150,000 companies, evaluates businesses on 21 sustainability criteria across four key pillars: environment, labor and human rights, ethics, and sustainable procurement.

In the latest assessment, KHS scored 86 out of 100 points, a sharp improvement from last year’s 75-point gold rating.

The company’s strengthened performance was attributed to an expanded guideline and certification management program, particularly improving its results in ethics and labor and human rights.

KHS also maintained its strong standing in environmental performance while continuing to advance in sustainable procurement.

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