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A PUBLICATION OF THE KAHL GROUP - Neuhaus Neotec

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A <strong>PUBLICATION</strong> <strong>OF</strong> <strong>THE</strong> <strong>KAHL</strong> <strong>GROUP</strong>


kahl group<br />

PREFACE<br />

Dear Business Friend,<br />

We are pleased to inform you on current developments of our Group in this new journal.<br />

Also in this issue of our journal we give priority to innovations within our Group.<br />

To be able to implement the new developments we need you, dear business friend, and<br />

your readiness to tread new paths with the assistance of our employees. After all, the<br />

success of your investment also matters to us. We are particularly proud of having won<br />

the Apprenticeship Award 2009 by the IHK (Chamber of Industry and Commerce) for our<br />

exemplary performance in in-company training. For one thing is certain: The qualification<br />

of our employees is a decisive factor for future success.<br />

Your<br />

Jan Behrmann & Joachim Behrmann<br />

02/03<br />

Photo: Hamburger Abendblatt Birgit Jaklitsch / Birgit Schcking.


<strong>THE</strong> <strong>KAHL</strong> <strong>GROUP</strong>


TABLE <strong>OF</strong> CONTENTS<br />

AmAnDuS <strong>KAHL</strong><br />

06 »Kahl reinvents the wheel«<br />

08 Large-scale plants for wood pelleting –<br />

Plantation Energy Australia<br />

09 Residue-free recycling of waste tyres –<br />

From tyres to granulate<br />

10 Recycling of polyethylene terephthalate<br />

(abbreviation PET)<br />

11 Research & Development at Amandus Kahl<br />

12 The sports activities of the Kahl Group<br />

14 Application the flat die pelleting press 14-175<br />

16 A complete feedmill with innovative<br />

technologies in Tatarstan<br />

18 Coke dust pellets for steel smelting furnaces<br />

19 Success in the oil palm industry –<br />

Kahl has taken the first flat die pelleting press for<br />

pellets from empty fruit bunches into operation<br />

19 The Crown Expander –<br />

Pelleting without a pelleting press<br />

20 HoweE Eberswalde –<br />

The first pan grinder mill applied in practice<br />

SPECIAL<br />

nEuHAuS nEOTEC<br />

21 Finer than fine<br />

22 Energy saving due to preheating of coffee beans<br />

23 new drum roaster CTR - 3000<br />

24 Particle technology<br />

25 GmP - Grinders<br />

25 Heinen Freezing<br />

25 Sunflower seeds perfectly roasted<br />

27 The perfect espresso<br />

28 Paulig<br />

29 Enlargement of Premises<br />

SCHuLE<br />

30 Oilseed processing plant<br />

for sunflower, soya and rape<br />

30 Start-up of a rice mill in Peru<br />

32 High nutritional value of durum wheat (bulgur)<br />

32 new ways of oats processing in Belarus<br />

33 Precision of separation at 1,000 tons<br />

per day in the oil industry<br />

33 Schule – Food Technology<br />

34 Bioethanol – Higher profit without shell<br />

34 nigeria – promotion and development<br />

of agricultural resources<br />

FROm OuR mAnuFACTuRInG DEPARTmEnT<br />

36 Expansion of die manufacturing building<br />

37 new bending machine for<br />

apparatus construction<br />

37 Award for exemplary vocational<br />

education and training<br />

04/05


amandus kahl<br />

»<strong>KAHL</strong> REINVENTS <strong>THE</strong> WHEEL – <strong>THE</strong> PAN GRINDER MILL!«<br />

our competitors say that the energy consumption of our pel-<br />

leting presses is higher as cylindrical pan grinder rollers run<br />

on a circular path and the resulting shearing effect makes our<br />

machine an energy guzzler. For decades we have been proving<br />

every day that this is not true. partly, we have eliminated this ef-<br />

fect by using conical rollers, mainly in order to achieve a further<br />

temperature reduction for example during hop pelleting.<br />

meanwhile we have acted on our competitors' suggestions and<br />

remembered what pan grinder rollers originally have been used<br />

for: for crushing various products, mainly grain. Even when driv-<br />

en by muscle power pan grinder rollers have been a well-proven<br />

technology for centuries. But joking aside – also in the recent<br />

past kahl pelleting presses have always had the edge on other<br />

processes when it comes to pelleting fibrous products such as<br />

straw, grass or dried beet pulp. Thanks to the much-maligned<br />

shearing effect, the machine can process also coarse particles<br />

without any problem. The fact that it is used for crushing waste<br />

tyres impressively proves the efficiency of the kahl pelleting<br />

press. nowadays, wood pelleting has gained worldwide acceptance.<br />

Wood pellets are trading goods and in their quality as a<br />

fuel they definitely compete with oil and gas. as the demand for<br />

pellets increases, the demand for saw dust and wood shavings<br />

increases as well. as an alternative, wood chips can be processed<br />

which, however, have to be crushed in wet condition before drying.<br />

Traditional methods such as knife ring flakers or hammer<br />

mills can be used, yet they have several disadvantages. In fast<br />

running mills there is a tendency to product clogging if the input<br />

product is too wet. Wood chips may have a water content of up<br />

to 50 % and hammer mills have to be aspirated, the exhaust air<br />

being discharged through a filter.<br />

Fast running mills produce sound emissions which are far beyond<br />

the limit of 85 dba. knife ring flakers, well-proven machines<br />

in the chipboard industry, require regular maintenance<br />

at short intervals. The match-like structures of the product may<br />

cause problems in conveying elements and the downstream pelleting<br />

plant. Questions often generate ideas: What happens to<br />

wet wood chips in a kahl pelleting press? answer: due to the<br />

high moisture content the pellets will disintegrate. so what? If<br />

the pellets disintegrate, this means that the particles are small<br />

enough to have fitted through the die holes before! Intriguing,<br />

isn't it? of course, it is not as easy as that. But this questionand-answer<br />

game led to first trials in the pilot plant and later in<br />

practice – successful tests which raised new questions:<br />

• Which throughput is reached at which moisture content?<br />

• Which influence do the input particle sizes G 30 or G 50 have?<br />

• Which are the optimum perforations of the die?<br />

• How can the output product be dried?<br />

• Can we even do without wet grinding?<br />

• What shall we call this new technology?<br />

• How will the markets react to this new technology?<br />

View into the pan grinder mill


This new idea aroused immense enthusiasm in our technical<br />

and sales departments so that numerous measurements were<br />

carried out in various fields of application and the majority of<br />

all open questions could be answered rapidly. The markets' re-<br />

action to this new technology has been more than positive. A<br />

customer in Poland bought the first »pan grinder mill« before<br />

the machine had been officially released for sale. Today, this<br />

pan grinder mill type 37-850 processes 6 – 7 t/h of G30 wood<br />

chips. The crushed wood chips are dried to a residual mois-<br />

ture content of approx. 10 % in a drum drier and subsequently<br />

they are directly pelleted. Thus, the answer to the question if<br />

dry grinding can be dispensed with is yes. Later, this was confirmed<br />

in our plant at HoWee at Eberswalde. Our live demonstrations<br />

of the pan grinder mill at trade fairs in Stuttgart and<br />

Hanover were a complete success and Kahl was awarded an<br />

innovation prize for the pan grinder mill in Stuttgart.<br />

Which advantages does the pan grinder mill have when used for<br />

crushing wood chips? The following arguments are convincing:<br />

• No aspiration is required.<br />

• The sound emissions are below 75 dbA<br />

• Drying of the defibered wood is more economic.<br />

• The fibres produced by the pan grinder mill<br />

ensure an improved pellet quality.<br />

• Dry grinding can be dispensed with if the<br />

die perforation is 6 mm<br />

• High moisture contents do not cause problems but<br />

reduce the specific energy consumption<br />

06/07<br />

nothing now can stop a rapid market relaunch of the pan<br />

grinder mill. This »new« machine has been used successfully<br />

as a pelleting press all over the world and has been optimised<br />

throughout decades. The wide-ranging type series covers every<br />

capacity requirement. After a demonstration at a trade fair, a<br />

large German sawmill cancelled the hammer mill that had already<br />

been ordered and ordered a pan grinder mill for about<br />

20 t/h wood chips G30 instead.<br />

We receive inquiries for the new technology from the woodprocessing<br />

industry almost every day. new complete plants<br />

are equipped now with Kahl technology including wet grinding<br />

lines of wood chips, the belt drier and pelleting lines.<br />

Amandus Kahl is the only manufacturer to cover such a wide<br />

range of processes in a modern wood pelleting plant with their<br />

own machines.<br />

The capacity of the pan grinder mill is up to 40 t/h


amandus kahl<br />

POWERFUL LARGE-SCALE PLANTS<br />

FOR WOOD PELLETING IN AUSTRALIA<br />

In the meantime 2 plants have started production.<br />

Plantation Energy Australia, one of the largest Australian manu-<br />

facturers in the international wood pellets business, has chosen<br />

Amandus Kahl as their exclusive partner for the production of<br />

wood pellets.<br />

The plants will produce industrial and high-quality premium pel-<br />

lets on the basis of eucalyptus and pine wood from local planta-<br />

tions. The central part of every production line is the pelleting<br />

plant with 4 flat die pelleting presses type 60-1250 each - the<br />

flagship among the wood pelleting presses. With its sturdy de-<br />

sign and a drive power of 2 x 200 kW, this pelleting press is the<br />

most suited machine for the high demands arising from these<br />

enormous production capacities. Plantation Energy is based in<br />

Western Australia with offices in melbourne and Perth and is<br />

funded by Denham Capital, a leading private equity firm in the<br />

energy sector operating world-wide.<br />

The company with production facilities in Albany, Western Aus-<br />

tralia, is managed by an experienced executive team. Further<br />

manufacturing capacity is under development in the "Green Tri-<br />

angle" region between Victoria and South Australia. Plantation<br />

Energy Australia has positioned itself as a market leader in the<br />

production and supply of biofuel.


08/09<br />

ENVIRONMENTALLY FRIENDLY AND RESIDUE-FREE RECYCLING <strong>OF</strong> WASTE<br />

TYRES FROM TYRES TO <strong>THE</strong> GRANULATE IN ONLY 2 STEPS<br />

For more than 10 years, the kahl technology has been well<br />

known in waste tyre recycling. The convincing technology of<br />

granulation using flat die pelleting presses has established itself<br />

in the market. With the foundation of the public recycling as-<br />

sociation signus Ecovalor in may 2005, spain introduced com-<br />

prehensive legal provisions for tyre recycling. The plant supplied<br />

to our customer in the north-east of madrid (annual capacity<br />

30,000 t of waste tyres) is based on a design with a two-stage<br />

grinding plant and has been started-up in record time. The pro-<br />

duced granulates are to be used for sports venues surfaces, im-<br />

pact protection devices and for road construction. In the united<br />

arab Emirates, tyres used to be disposed to an ever-expanding<br />

landfill (20 million tyres) outside the city limits for decades. The<br />

company Emirates recycling llC, a member of the al rostamani<br />

group, charged amandus kahl with the construction of the larg-<br />

est waste tyre plant to date with an input capacity of 10 t/h.<br />

another plant made by kahl was put into operation in north-<br />

ern greece in the year 2009. Close to the border with Bulgaria,<br />

a waste tyre recycling plant with a capacity of 15,000 tons per<br />

year was built. The kahl technology has also been convincing<br />

in our neighbouring country austria. In 2009, the granulators<br />

and cutting mills in austria's largest waste tyre recycling plant<br />

were dismantled and two new granulation lines equipped with<br />

kahl pelleting presses of the type 60-1500 were erected. This<br />

exchange allows the production of granulate in only two crush-<br />

ing steps.<br />

Figure 1 – 2 granulation plant, spain<br />

1<br />

2


amandus kahl<br />

RECYCLING <strong>OF</strong> POLYETHYLENE TEREPHTHALATE (ABBREVIATION PET)<br />

The development of the process for PET recycling has been underway for more than 2 years now. In cooperation with the<br />

company LCI, the Amandus Kahl representation in the uSA in the field of chemistry, and a well-known u.S. company, a proc-<br />

ess was developed that allows the production of a granulate from shredded PET bottles which can be directly reused for the<br />

production of PET bottles. Since the newly developed process is very sensitive, it was necessary to adapt the corresponding<br />

machines to the process. The process functions with very short effective bores at relatively high temperatures (about 130 °C);<br />

thus the machines have to be operated with oil cooling and special lubricants as well as with special devices. The development<br />

is based on the pelleting press type 33-390 the data of which was used to design the current production presses type 38-600.<br />

Since the beginning of 2009, two plants have been put into operation,<br />

which achieved the calculated expectations of quality and quantity right from the start.


RESEARCH & DEVELOPMENT AT AMANDUS <strong>KAHL</strong><br />

In the highly dynamic environment of a medium-sized company<br />

with a vast field of activities, the classical department of re-<br />

search & development (R&D) has to be open-minded and flex-<br />

ible in order to meet the high demands of our customers with<br />

regard to innovations in process engineering and plant and me-<br />

chanical engineering.<br />

The success in recent years, and in fact for decades, proves that<br />

the company's high investments in the field of R & D and in<br />

the pilot plant have been justified. Our philosophy in research<br />

and development is to advance the well-known main machines<br />

such as flat die pelleting press, expander, belt drier, etc. and<br />

to modify and optimise them for new markets and processes<br />

so that they can be used also in new and yet to be discovered<br />

niche industries.<br />

In the following some examples of the adaptation of such plants<br />

to new industrial sectors:<br />

• Grinding concepts for cereals for the production of bioethanol<br />

• Optimisation of the pelleting presses for wood pelleting<br />

• Shaping of distillers grains (bioethanol)<br />

• Extruder in the semi-luxury items industry<br />

• Pan grinder mill for grinding (article in this Journal)<br />

• Fabric belt drier<br />

• Crown Expander<br />

Other examples of process engineering solutions with optimum<br />

adaptations of the machines:<br />

• Extruder (on the basis of the expander) => fish feed plants<br />

• Pelleting press 1500<br />

• Eco-processor<br />

• Flat die pelleting press in the pharmaceutical sector<br />

• Continuous cooker /vacuum coater<br />

• Waste tyre recycling plants<br />

• Batch mixer for preheating of green coffee<br />

10/11<br />

The ideas and developments are the result of the cooperation<br />

of many departments and of the interaction with institutions,<br />

our customers, prospective buyers and associates of our company.<br />

The development is never completed when the first machine<br />

is fabricated or the first process is implemented. These<br />

innovations are always accompanied by the staff of our R & D<br />

department or the pilot plant who assist our customers during<br />

start-up and production.


amandus kahl<br />

<strong>THE</strong> SPORTS ACTIVITIES <strong>OF</strong> <strong>THE</strong> <strong>KAHL</strong> <strong>GROUP</strong><br />

It started about 10 years ago: Our former works manager, mr.<br />

Gallus, had infected some of his colleagues with his enthusiasm<br />

for bicycle racing: They signed up for the HEW Cyclassics as the<br />

event was called back then, a cycling classic held in Hamburg<br />

every year. They started training together in spring and divided<br />

into several »<strong>KAHL</strong> teams« competing over the distances of 50<br />

km, 100 km or 150 km. This enthusiasm has grown every year;<br />

nowadays the participation in the Cyclassics has become a tradition<br />

in the company Kahl with a steadily increasing number<br />

of participants (unfortunately, only one female colleague has<br />

taken part in the race, so far). Even some of our agents from<br />

abroad let themselves be infected with our enthusiasm, for example<br />

mr. Götti from Switzerland and mr. Codega from Italy.<br />

We always appreciate their support!<br />

In 2009, four colleagues put the icing on the cake with an<br />

extraordinary performance: They took part in the »Vätternrundan«,<br />

a non-stop (!!!) 300 km bicycle ride around the lake<br />

Vättern in Sweden. not only the 300 km ride is a fabulous performance<br />

– also braving the weather is a real challenge: Wind,<br />

rain, 9 °C. All four colleagues crossed the finishing line safe and<br />

sound. Congratulations!<br />

Cycling was not to remain the only activity. Some years ago,<br />

our football players decided that they wanted an opportunity<br />

to play a match »within the company«: now, it has become a<br />

tradition to arrange a football tournament with subsequent<br />

barbecue right before the summer holiday every year. The last<br />

tournament was won by the team of our managing director<br />

mr. Joachim Behrmann (70) who never fails to take part. Sport<br />

keeps you young – that is his motto – and he himself is the best<br />

proof of it! Those colleagues who prefer moving their brains<br />

to moving their legs have started yet another tradition: Every<br />

year, we arrange a skat tournament (a card game passionately<br />

played in Germany) which has become so popular that even our<br />

retirees enter the date in their diaries well in advance.<br />

Fig. 1 "magic dribblers" in action<br />

Fig. 2–4 our team of cyclists is remarkably successful every year<br />

»Sport keeps you young -<br />

that is his motto - and he himself is<br />

the best proof of it! «<br />

1


12/13<br />

3 4<br />

2


amandus kahl<br />

<strong>THE</strong> FLAT DIE PELLETING PRESS 14-175<br />

IN GMP/FDA CONFORMING DESIGN<br />

Due to the increase of the world population and the higher life<br />

expectancy combined with the desire for a better quality of life,<br />

the pharmaceutical industry holds a good position in the mar-<br />

ket. The high demand for drugs earned the pharmaceutical en-<br />

terprises high sales and profits. Apart from the drug discovery,<br />

the pharmaceutical enterprises have to attach great importance<br />

to optimising their production processes to meet the demand<br />

for low costs. Yet, the possibilities for cost reduction are limited.<br />

The production costs account for a significant proportion of the<br />

total costs. In connection with optimisation measures, flexibility<br />

and automation are important tools for cost reduction. Also<br />

alternative processes or new machines – even from outside the<br />

industry but well-proven ones, are discussed. All plant components,<br />

however, have to conform to the high requirements on<br />

hygienic standards. This includes also constructional features<br />

such as the absence of dead space, electropolished surfaces,<br />

or validated cleaning concepts. They have to conform to GmP<br />

(Good manufacturing Practice) and FDA (Food and Drug Administration)<br />

standards.<br />

The following description of the process of agglomeration by<br />

compression using flat die pelleting presses explains the advantages<br />

of this process over traditional processes as well as<br />

the experience with the production of granules gained in this<br />

industry, so far. Basically, granules are preparations that consist<br />

of solid and dry grains, each grain being an agglomerate of<br />

powder particles with a sufficient stability to allow for different<br />

manipulations. Granules contain one or more active agent.<br />

They can either be used directly as drugs or as an intermediate<br />

product for the production of other dosage forms such as capsules<br />

or tablets. The granulation of powdery tablet masses is a<br />

common and necessary process.<br />

The goals of granulation are:<br />

• No segregation of the individual components<br />

• Improved flowability<br />

• Improved proportioning accuracy due to small granules<br />

• Good tabletability<br />

• Modification of properties in the tablet (for example<br />

increase of abrasion resistance and improvement of<br />

decomposition characteristics)<br />

mainly, we distinguish between two process variants in the<br />

production of granules:<br />

• Moist granulation<br />

• Dry granulation / melt extrusion.<br />

moist granulation (i.e. of a powder mixed with water or a<br />

water-binder solution) is realised for example with:<br />

• Fluid bed agglomerators<br />

• High shear-intensity mixers (batchwise).<br />

• Extruders (continuously).<br />

However, drying of the wet granules is required. Drying is usually<br />

realised batchwise in the fluid bed (-> see page 24 - Particle<br />

Technology).<br />

The extrusion process is also a proven technology for the compaction<br />

of bulk products. In the pharmaceutical sector, for example<br />

twin-screw extruders with subsequent spheronisation<br />

are used. Due to the cost constraints mentioned above, machines<br />

for agglomeration by compression can be considered.<br />

Apart from roller compactors (production of oblong strands or<br />

flakes), also extrusion presses or flat die pelleting presses can<br />

be used. For this purpose, Amandus Kahl GmbH & Co. KG has<br />

further developed the well-known laboratory machine 14-175.


1 2<br />

Fig. 1 pelleting press type 14-175 Fig.2 pelleting elements pan grinder rollers and die<br />

For many years, the flat die pelleting press has been successfully used for granulation /compaction in the pharmaceutical indus-<br />

try- also on a production scale. It offers important advantages. The latest generation of the flat die pelleting press 14-175 in GmP<br />

/ FDA conforming design has not only been advanced constructionally. Its process technology has also been examined in other<br />

pharmaceutical applications. This press type was extensively examined at the Faculty of Pharmaceutical Technology at the univer-<br />

sity of Düsseldorf (Prof. Kleinebudde) with regard to moist extrusion and melt extrusion processes. The flat die pelleting press was<br />

declared an appropriate machine for pharmaceutical applications. It was also used successfully for processing lipid formulations in<br />

a research project of the university of Düsseldorf. The compression or extrusion of the lipids was realised under pressure and at a<br />

temperature below the melting temperature of the lipids (thermomechanical process). The decisive advantage over melt extrusion<br />

lies in the fact that the lipids are treated gently and thus the lipid structure largely remains intact.<br />

14/15


amandus kahl<br />

A COMPLETE FEEDMILL WITH INNOVATIVE<br />

TECHNOLOGIES IN TATARSTAN<br />

The feed plant was designed by Amandus Kahl with the main<br />

machines being of their supply. The entire plant was built in the<br />

record time of one and a half years and has been designed as<br />

a seven-storey building with a height of 40 meters. 24 silos for<br />

raw materials and 24 silos for finished products are available.<br />

The silos are 19 m high, have a diameter of 2.5 m and a volume<br />

of 95 m³ (Fig. 1).<br />

The automated production line achieves a capacity of about<br />

20 t/h of finished product. The innovative batch system allows<br />

for rapid formula change. The raw materials are proportioned<br />

into the batch weigher and ground using the hammer mill<br />

(Fig. 3). The ground mixture is either fed into the plant for fin-<br />

ished products or into the pelleting line with expander. This pel-<br />

leting and/or expansion process is automated and commences<br />

with the mixture of the crushed raw materials in a mixing con-<br />

ditioner (Fig. 1).<br />

Feedstuff for all species of production animals of differing ages<br />

and for different production targets are produced. mash feed,<br />

crumbles (pellets), expanded feed or structurised expanded<br />

feed can be produced. Expandat ® is produced with an annular<br />

gap expander. Expandat ® is a compound feed which has been<br />

exposed to hydrothermal treatment by the expander (Fig. 4) and<br />

which has been produced as a granulate, without pelleting.<br />

The specialists of the feedmill can individually optimise the<br />

feed formulae according to the customer's demands. This op-<br />

timisation will not only take into account the age, but also the<br />

performance as well as the husbandry method of the animals.<br />

Furthermore, the customer's production targets are observed<br />

by optimising the feed rations. If needed, the specialists of the<br />

feedmill visit their customers in their factories in order to ana-<br />

lyze and solve problems on site.<br />

Fig. 1 The factory has a capacity of 20 t/h<br />

Fig. 2 – 3 pelleting press and hammer mill<br />

Fig. 4 annular gap expander, Fig. 5 Conditioner mk, Fig. 6 Belt drier<br />

1


2<br />

3<br />

16/17<br />

4<br />

5<br />

6


amandus kahl<br />

ASIA: COKE DUST PELLETS FOR STEEL SMELTING FURNACES<br />

The pellets are fed into blast furnaces for steel production.<br />

Acting as a service contractor of the major Asian steel manu-<br />

facturer, our customer processes coke dust from the filters<br />

of coke lines. The coke dust is provided free of charge. The<br />

value of the pellets might correspond to that of coke which<br />

has varied between $ 190.00, and 680.00 $ in recent years.<br />

Our customer imports mainly coking coal for his own coking<br />

plants, to a certain extent he also imports ready made coke.<br />

The aim is to reduce the coke import and to optimise his<br />

own coke production process in order improve the quality<br />

of the produced coke. This includes a more efficient use of<br />

the dust produced in the coking plants.<br />

At present 8 pelleting lines equipped with pelleting presses<br />

type 39-1000 are in operation. Their throughput capacity<br />

is 5 – 6 t/h each. Pellets with a diameter of 4.5 mm are<br />

produced.<br />

Coke dust pellets meet two important goals. First, full-value<br />

coke is obtained and the dusts do not have to be sold below<br />

their value - after all, the dusts have caused high cost<br />

for raw material, transport and the coking process. Second,<br />

due to their homogeneity, the pellets have a defined sinking<br />

behaviour in the blast furnace, which improves the steel<br />

production process.<br />

Fig. 1 pelleting press type 39-1000<br />

Fig. 2 Empty fruit bunches (l.) and biomass pellets (/r.)<br />

Fig. 3 Crown expander<br />

1<br />

2<br />

3


SUCCESS IN <strong>THE</strong> OIL PALM INDUSTRY -<br />

<strong>KAHL</strong> HAS TAKEN <strong>THE</strong> SECOND FLAT DIE PELLETING PRESS FOR<br />

PELLETS FROM EMPTY FRUIT BUNCHES INTO OPERATION<br />

In 2009, the first flat die pelleting press for the production of biomass pellets from Empty Fruit Bunches was put in operation in<br />

malaysia. meanwhile our customer successfully commissioned the second pelleting press type 45-1250 for Empty Fruit Bunches - a<br />

pelleting press 45-1250 with a drive power of 315 kW for a capacity of up to 5 t/h. The pellets are intended for example for energy<br />

production and for refinement into ethanol in the BTL process. With pelleting plants for oil palm fronds, Amandus Kahl has already<br />

gained an excellent reputation in malaysia and regularly delivers pelleting presses to that country. EFBs have been the centre of<br />

interest of the biomass industry for some time as large quantities of EFBs are produced as a residue in palm oil mills, which means<br />

that they do not produce any transport costs for raw material supply. The largest producers of palm oil are malaysia and Indonesia.<br />

Palm oil is also produced in Africa, South America and other Southeast Asian countries.<br />

<strong>THE</strong> CROWN ExPANDER: PELLETING WITHOUT A PELLETING PRESS<br />

Our customers operate more than 600 expanders worldwide.<br />

In the u.S.A. for example, turkey fattening feed is expanded<br />

before pelleting in most cases. The annular gap expander has<br />

proved to be a good solution also in other fields such as starch<br />

modification or the oilseeds-processing industry. And last but<br />

not least, we have developed our Kahl extruder on the basis<br />

of the expander. With the extruder even higher mechanical<br />

energy inputs and modification degrees can be realised, and<br />

the products – fish feed, petfood, and snacks – can be pelleted<br />

or given other defined shapes. For quite some time, there has<br />

been a clear tendency towards coarse grinding of feed.<br />

Amandus Kahl remembered that in the annular gap expander,<br />

coarse grinding structures remain largely unchanged, although<br />

the product is exposed to a strong pressure and kneading effect.<br />

The pressure load in the expander acts on all sides of the<br />

coarse particles. The homogeneous pressure distribution on<br />

the entire particle circumference is supported by embedding<br />

these coarse particles in a pasty moist matrix of fine particles.<br />

Another advantage lies in the fact that the finer particles are<br />

agglomerated during expansion and thus are transformed into<br />

coarse structures. It occurred to our engineers that they might<br />

equip the expander outlet with an annular die similar to that of<br />

a pelleting press. A die without pan grinder rollers to be more<br />

precise, as they wondered: Should the high internal pressure<br />

of the expander not be able to press the finished product right<br />

through the round or oblong bores in the die ring, thus making<br />

the pressing and crushing effect of pan grinder rollers superfluous?<br />

– A rotating cutter was designed, meant to cut the product<br />

18/19<br />

strands leaving the die to uniform pellet lengths. So the »Crown<br />

Expander« was born. The machine owes its name to the crown<br />

form of the first dies which were provided with slits instead of<br />

bores.<br />

One important component of the annular gap expander remained<br />

unchanged in the Crown expander: The hydraulically<br />

moveable cone. This cone can be moved into and out of the<br />

crown die at the outlet end. Depending on the position of the<br />

cone in the die, more or less die bores are open for the production<br />

of pellets. Thus the pelleting process is easy to control by<br />

simply varying the cone position – in contrast to conventional<br />

extrusion processes which require die changes or far more<br />

complicated control mechanisms.<br />

The results obtained so far, have met every expectation, which<br />

means that we succeeded in the proverbial »squaring of the circle«:<br />

The Crown expander produces pellets or other regularly<br />

shaped structures while preserving coarse particles and simultaneously<br />

agglomerating fine and finest components. The positive<br />

nutritional effect of expansion is an additional advantage<br />

which traditional pelleting does not offer.<br />

The crown expander – an ideal example of a successful further<br />

development taking into account aspects of animal nutrition<br />

and process technology.


amandus kahl<br />

HOWEE EBERSWALDE – <strong>THE</strong> FIRST PAN GRINDER MILL APPLIED IN PRACTICE<br />

For years, the wood pelleting plant of the company HoweE near<br />

Eberswalde (north of Berlin) has worked perfectly. The main<br />

components of this plant are a belt drier with a length of 40<br />

m and three pelleting presses type 39-1000. The <strong>KAHL</strong> scope<br />

of supply includes the belt drier with prebin, the silo for dried<br />

wood chips, the pelleting and cooling plant as well as the loading<br />

silos. The plant has been designed for a capacity of 7.5 t/h<br />

of pellets in its final construction stage. A special feature of the<br />

plant is the fact that there is no dry grinding unit. A chopper<br />

and a pan grinder mill type 45-1250 are arranged upstream of<br />

View into the pellet production plant<br />

the drier. Both devices provide a product with excellent conveying<br />

and pelleting properties. About 165 tons of DIn Plus pellets<br />

are produced in this plant with three pelleting presses in threeshift<br />

operation every day.


FINER THAN FINE<br />

ultrafine coffee grinding is a technology that requires a lot<br />

of know-how and precision. neuhaus neotec roll grinders set<br />

technical standards for this type of grinding.<br />

For the preparation of Turkish mocca for example, the roasted<br />

coffee is crushed to an almost floury fineness. ultrafine grind-<br />

ing takes it one step further – the roasted coffee is very finely<br />

ground so that there is no granular structure to be felt when<br />

rubbing the ground coffee between the fingers – it is simply<br />

ultrafine.<br />

With more than 40 years of experience in coffee grinding, neu-<br />

haus neotec offer roll grinders that represent state-of-the-art<br />

technology. The particle size of ultrafine grinding is approx. 50<br />

µm, with the gap width between the special rolls being below<br />

10 µ. With this process, a particularly fine and homogeneous<br />

ground product can be produced thanks to special roll drives<br />

and high-capacity cooling during the grinding process.<br />

A touch screen control system and a sensitive temperature<br />

monitoring system facilitate the control of the grinders. The<br />

special roll geometry and surface design in combination with<br />

separate drives ensure an extremely precise adjustment of<br />

the grinding degree. Furthermore, built-ups which can occur<br />

when grinding fine coffee, can be overcome by using a dynamic<br />

scraper system.<br />

Different sizes of the neuhaus neotec roller mills for ultrafine<br />

grinding with capacities ranging from 100 to 1000 kg per hour<br />

are available.<br />

Fig. 1 roll grinder Wms<br />

Fig. 2 superfine coffee<br />

20/21<br />

1<br />

2


nEuhaus nEoTEC<br />

ENERGY SAVING DUE TO PREHEATING <strong>OF</strong> C<strong>OF</strong>FEE BEANS<br />

In times of high raw material and energy costs, coffee roasters do not only have to consider the quality of their roasting processes;<br />

they also have to optimise these processes in terms of energy savings and cost reduction.<br />

An efficient way to save energy is preheating of the green coffee, which further optimises the already energy-efficient neuhaus<br />

neotec roasting plants.<br />

This is the functional principle of green coffee preheating: Prior to the actual roasting process, the green coffee batch is preheated<br />

to a temperature of about 100 °C in a preheating chamber before it is fed into the roasting chamber. The thermal energy stored in<br />

the beans can not only shorten the subsequent roasting process but also reduce the quantity of consumed energy during roasting,<br />

which in turn causes a reduction of CO2 emissions. neuhaus neotec offer two different systems which reduce energy costs by up<br />

to 25 % and CO2 emissions by about a quarter. Preheating does not only reduce costs and emissions, it also increases the capacity<br />

of the roasting machines by up to 20 %.<br />

green coffee preheating in a coffee roasting plant in southern germany


<strong>THE</strong> NEW DRUM ROASTER CTR - 3000<br />

neuhaus neotec complement their range of products by a roasting machine for traditional speciality roasting.<br />

The roasting plants of neuhaus neotec stand for an innovative and progressive convection roasting technique. About 20 years ago,<br />

the introduction of the RFB roaster covering the entire range of roasting times and qualities laid the foundations of the internation-<br />

al success of the roasting plant manufacturer. For the traditional recipes of speciality roasters, neuhaus neotec now complement<br />

their range of products by a new drum roaster that has been tailor-made for longer roasting times and classical roasting concepts.<br />

The CTR - 3000 has a capacity of more than 3 t/h and roasts batches from 480 kg to 640 kg. However, roasters for lower capaci-<br />

ties are also available. Even though the drum roaster is especially suited for traditional roasts, it also offers new technical solutions,<br />

high-quality safety technology and a modern energy concept. With the new CTR - 3000, neuhaus neotec can provide also those<br />

roasting plants with complete lines which favour the drum roaster. Thus they profit from neuhaus neotec's well-known compe-<br />

tence as well as from considerably easier and more reliable planning, installation and start-up. meanwhile, the first CTR has started<br />

production in a major German roasting plant. now it works round-the-clock to the customer's complete satisfaction.<br />

The CTr-3000<br />

22/23


PARTICLE TECHNOLOGY<br />

With the establishment of the new department »PARTICLE<br />

TECHnOLOGY« neuhaus neotec has set the course for a suc-<br />

cessful future. With our process-oriented research we open up<br />

fields of application not only in the coffee industry but also in<br />

the pharmaceutical, chemical, and food and semi-luxury items<br />

industry. In doing so we profit from synergy effects with the<br />

<strong>KAHL</strong> Group. In may 2009, we presented ourselves jointly for<br />

the first time on the occasion of the world's largest trade fair for<br />

process engineering, the ACHEmA in Frankfurt.<br />

/ nEuhaus nEoTEC<br />

The core competence of the new department are continuous<br />

fluidized bed processes and roller mills for low-dust grinding.<br />

Fluidized bed processes are efficient and due to the intensive<br />

exchange of heat and material they are the first choice if ther-<br />

mal treatment of bulk products (drying and cooling) and the<br />

formation of particles from powders (agglomeration) or liquids<br />

(spray granulation) are concerned. Top and bottom spraying<br />

processes in the fluidized bed have gained acceptance for the<br />

production of instant products and granulates for subsequent<br />

compaction, for example. There is no reason not to use continuous<br />

processes (reproducible, fully automatic, product quality).<br />

Even for capacity ranges of 10 kg/h and less this process has<br />

been applied successfully in the pharmaceutical industry, since<br />

a better understanding and control of the process are possible<br />

due to the constant conditions.<br />

For this reason the department »Particle Technology« of neuhaus<br />

neotec maschinen- und Anlagenbau GmbH has developed<br />

a new continuous fluidised bed pilot plant for the capacity<br />

range of 5 to – 50 kg/h, with which an upscale is possible without<br />

difficulties due to the flexible plant configuration and on<br />

the basis of a long-standing know-how.<br />

The outstanding feature of this modular and thus mobile<br />

plant is an exchangeable product bin which is designed individually<br />

for the different processes, such as drying, agglomeration<br />

and spray granulation, and which covers different capacity<br />

ranges due to variation of the distribution plate. The<br />

plant is installed in the GmP area of the pilot plant building<br />

and has been available for tests since the beginning of 2010.<br />

pilot plant 20/4


GMP-GRINDER<br />

Our roller mills are used for applications in the chemical, min-<br />

eral and metal industry, in the food industry and in the pharma-<br />

ceutical industry.<br />

The well-established laboratory grinder LWm 100 has been de-<br />

veloped and improved especially for demanding applications<br />

in the pharmaceutical and chemical industry or in the food in-<br />

dustry. The new design with drive system and control elements<br />

housed together in one stainless steel case allows quick and<br />

easy cleaning. All product-contacting parts are designed in<br />

stainless steel 1.4404 (316 L) with a surface quality of < 0.8 µm.<br />

gmp conforming roller mill type lWm - 100<br />

HEINEN FREEzING<br />

The Heinen Freezing GmbH has more than 25 years of experi-<br />

ence with regard to the process steps of pasteurization, freez-<br />

ing, cooling and conditioning in industrial food processing.<br />

Since January 1, 2010 the <strong>KAHL</strong> Group has held a majority of<br />

shares in this company.<br />

neuhaus neotec continues the brand »heinen drying«<br />

since the beginning of 2010<br />

24/25


In Eastern Europe, roasted sunflower seeds are a popular »in between« snack. With the rg roasters of neuhaus neotec these treats<br />

can be processed without problems.<br />

Flexibility and simple operation are two characteristics that define the rg specialty roasters of neuhaus neotec. But these attributes<br />

do not only relate to the roasting of coffee beans. also other products, such as sunflower seeds, pumpkin kernels, nuts and Chicory<br />

can excellently be processed with the innovative and flexible hot-air roasting technology of the neuhaus neotec roasters. recently<br />

the fourth project for an rg roaster for sunflower seeds could be completed in Eastern Europe. The rg 100 and rg 150 roasting<br />

machines are designed to roast 1000 or 1500 kg per hour.<br />

roasting is realized exclusively in a rotating motion in the hot-air current. This process and the excellent mixture provide uniform<br />

roasting of the product. The simple design of the plant, without mobile parts in the roasting or cooling chamber, ensures low main-<br />

tenance requirements.<br />

/ nEuhaus nEoTEC<br />

SUNFLOWER SEEDS PERFECTLY ROASTED


<strong>THE</strong> PERFECT ESPRESSO<br />

neuhaus neotec has proved over and over again that the tried<br />

and tested rFB (rotating Flexible Batch) roasting system meets<br />

the most varied requirements. not only does this process com-<br />

bine maximum production consistency with low energy con-<br />

sumption and maintenance requirements – rFB roasters also<br />

stand out due to their flexibility covering the whole range of<br />

roasting conditions.<br />

In particular, the very short response times, which the system<br />

owes to the low heat capacity of the roasting chamber, enable<br />

advanced methods of exerting influence on the roasting process<br />

to be applied, such as profile roasting and copy roasting – pro-<br />

cesses which were developed and tried by neuhaus neotec a<br />

long time ago.<br />

Today, many big coffee roasters prefer the rFB especially for<br />

their espresso roasts. The low air temperature and gentle pro-<br />

duct treatment ensure a result that is second to none. as es-<br />

presso market requires varied nuances of flavour, the rFB is<br />

the appropriate machine when it comes to producing perfect<br />

espresso.<br />

Capacities for espresso roasting: up to 4 t/h.<br />

26/27


PAULIG<br />

Advanced technology with a spectacular architecture<br />

In summer 2009, one of the largest newly built coffee roasting<br />

plants in the world started operation in Helsinki, Finland. neu-<br />

haus neotec supplied almost the complete logistics and techno-<br />

logy for the new roasting plant of Gustav Paulig Ltd.<br />

/ nEuhaus nEoTEC<br />

In summer 2009, the largest roasting plant that had been built<br />

worldwide in that year started operation. The coffee roasting<br />

plant is located in the Vuosaari Harbour in the Finnish capital<br />

Helsinki and produces up to 5 tons of roast coffee per hour. This<br />

was a huge project which required not only the construction of<br />

one of the largest roasting plants in the world but also the in-<br />

tegration of individual lines of the former Paulig roasting plant<br />

in Finland.The interior of the roasting plant as well as the silo<br />

building was planned and constructed by the German company<br />

neuhaus neotec which planned and supplied the entire logis-<br />

tics and technology from the green coffee receiving facilities to<br />

the packing lines with the exception of the roasting machines.<br />

Project manager Wilhelm mittelstädt of neuhaus neotec refers<br />

to the construction of the new roasting plant as »one of the<br />

biggest projects I have ever planned and realised«. The preparatory<br />

works of this construction project lasted several years. The<br />

actual cooperation for the project began with the submission<br />

of a first offer in summer 2006. Three years later, the major<br />

part of the new roasting factory was finished and could be put<br />

into operation. until the end of September, the new roasting<br />

plant already exceeded the roasting capacity of the former Paulig<br />

roasting plant in Finland. The main packing lines for ground<br />

coffee, for example, have a capacity of four tons per hour. Five<br />

large grinders crush the roasted beans. In total, there are 45<br />

silos for the storage of ground coffee.<br />

Paulig divided the project into three process sections: (1) the<br />

green coffee process (receiving, quality control, storage, and<br />

blending), (2) the roasted coffee process and (3) the ground<br />

coffee process including packing. The project manager characterizes<br />

the ground coffee transport as the most complicated<br />

task of the entire construction of the new plant. The complexity<br />

of the task consisted of planning and achieving a line capacity<br />

of five tons of coffee per hour which are ground with high<br />

flexibility and redundancy in five grinders and have to be rapidly<br />

packed. now he has every reason to be satisfied with himself<br />

and his staff. meanwhile, the factory produces more than a<br />

hundred million coffee packs per year.<br />

DAtA oN tHE RoAStING FACtoRy<br />

area: approx. 32,000 m²<br />

Volume: approx. 345,000 m 3<br />

length x width: approx. 300 x 150 m 2<br />

highest point: approx. 40 m<br />

lowest point: approx. 12 m<br />

- green coffee receiving and storage<br />

- Coffee roasting process<br />

- Coffee grinding process and transport<br />

- packing and palleting<br />

- storage unit<br />

- Control room<br />

- storage for mechanical equipment<br />

- production offices<br />

Total investment: approx. 120 million Euro


Fig. 1 Conveying plant for ground coffee at paulig<br />

Fig. 2 Conveyor for ground coffee at paulig<br />

1<br />

2<br />

ENLARGEMENT <strong>OF</strong> PREMISES<br />

new building with pilot plant at ganderkesee<br />

28/29<br />

For some months now, the 105 employees of nEuHAuS nEOTEC<br />

do not only have had more workspace, but also a new pilot plant<br />

where the two most important fields of activity – coffee processing<br />

and particle technology – are united under one roof.<br />

Apart from a new generous entrance area, the ground floor of<br />

the annexe building mainly accommodates the central part, i.e.<br />

the new pilot plant with a surface of about 400 m². Enough<br />

space for the research and development department where<br />

plants and installations are tested according to the customers'<br />

demands and adapted to the customers' products. These customers<br />

are mainly companies from the food and semi-luxury<br />

items industry and the chemical and pharmaceutical industry.<br />

The upper floor has a surface of 500 m² for new offices and<br />

modern conference rooms.<br />

Thanks to the the seven-digit investment in the annexe building<br />

the managing director mr. Gustav Lührs considers the location<br />

Ganderkesee to be well prepared for future orders and projects.<br />

Should nEuHAuS nEOTEC ever be running out of space in the<br />

industrial area Hoykenkamp (Ganderkesee), the foundation for<br />

a further extension will already have been laid - as the construction<br />

of another storey is possible at any time.


sChulE<br />

COMPETENCE IN <strong>THE</strong> FIELD <strong>OF</strong> EDIBLE OIL<br />

OILSEED PROCESSING PLANT FOR SUNFLOWER, SOYA AND RAPE<br />

Recently, a combined sunflower, soybean and rapeseed oil mill<br />

has been put into operation. The Schule scope of supply com-<br />

prises the entire conditioning unit including the oil-press as<br />

well as the fully automatic control system of the plant.<br />

The respective products are processed in the plant with the<br />

following process steps and throughputs: Sunflowers are proc-<br />

essed at a capacity of about 15 t/h. The process steps include<br />

cleaning, grading, husking, separation of husks, sorting with<br />

variably adjustable residual husk content in the husked grain<br />

fraction, and flaking upstream of the oil press. Soybeans are<br />

processed at a capacity of about 10 t/h. The process steps in-<br />

clude cleaning, grading, granulation, separation of husks on de-<br />

mand, and flaking before oil extraction. Rape is processed with<br />

START-UP <strong>OF</strong> A RICE MILL IN PERU<br />

In September, a rice mill (shelling, whitening, polishing, and col-<br />

our sorting) with a capacity of 15 t/h, equipped with machines<br />

of the company Schule was started up in Peru. A new whiten-<br />

ing technology is used in this mill. This innovative process is<br />

realised by means of the Verticone (VPC). Due to the flexibility<br />

and ease of operation of this machine, rapid optimisation of<br />

the process is possible, both for changing the types of rice to<br />

be processed and for varying quality requirements on the final<br />

product. Another advantage of the machine is its low energy<br />

consumption. Currently, the Verticone VPC 480 is the shelling<br />

machine with the highest capacity on the market.<br />

The polishing machine RPm 2A with the round screen basket,<br />

newly developed by the company Schule, is also used in the<br />

mill. With the use of this screen basket a uniform and improved<br />

polishing effect is achieved. The new shelling machine SHA has<br />

proven its high capacity when shelling tropical paddy. Although<br />

tropical paddy is difficult to shell, a capacity of 5 t/h with a<br />

a capacity of 12 t/h. The process steps include cleaning, grad-<br />

ing, and flaking upstream of the oil press. using the innovative<br />

Schule process and high-quality machines all the customers' re-<br />

quirements could be exceeded.<br />

The process ensures a controlled crude fibre content (protein<br />

content) of the extraction meal varying as required, as well as a<br />

minimal residual grain content in the shells/husks.<br />

shelling degree of more than 95 % was achieved. Because of<br />

the nature of the raw material processed in Peru, characterised<br />

by a high degree of impurities (chalky), and the high demands<br />

of the local market, the colour sorting machine DCD 320 was<br />

integrated into the plant.


Fig. 1 air sifter at ulerum<br />

Fig. 2 View into the new rice mill in peru Fig. 3 plant ulerum<br />

30/31<br />

2 3<br />

1


sChulE<br />

HIGH NUTRITIONAL VALUE <strong>OF</strong><br />

DURUM WHEAT (BULGUR)<br />

Due to its durability, its good storage and flow properties as well<br />

as its high nutritional value and easy preparation, bulgur has<br />

met with great interest in many parts of the world. In compari-<br />

son with other wheat products bulgur belongs to the nutrition-<br />

ally most valuable dishes. Bulgur is produced by means of soak-<br />

ing, continuous cooking and drying with subsequent husking<br />

and groating of the durum wheat. Recently, the company Schule<br />

has successfully started up a complete plant for the production<br />

of bulgur for the company Al-Gurair in Dubai.<br />

Fig. 1 Bulgur plant in the united arab Emirates<br />

NEW WAYS <strong>OF</strong> OATS PROCESSING<br />

IN BELARUS<br />

Schule received the order for the modernisation of an exist-<br />

ing oat mill and the installation of a quick-cooking and groat-<br />

ing plant on the basis of the new continuous pressure-cooking<br />

process by Schule. After the implementation of this project<br />

the customer achieved a significant increase in quality of the<br />

final product. The new Schule steaming and cooking process<br />

is energy-saving and thus increases the economic efficiency of<br />

the plant.<br />

Fig. 2 Belt cooker during start-up Fig. 3 Belt cooker in our pilot plant<br />

1<br />

2<br />

1. Scope of supply of the oat processing plant – It consists of the<br />

groups: Cleaning, husking, cutting, and control system<br />

2. Scope of supply of the continuous quick-cooking plant –<br />

It consists of the groups: Preparation, cooking, drying and<br />

control system<br />

3


PRECISION <strong>OF</strong> SEPARATION AT 1,000 TONS PER DAY IN <strong>THE</strong> OIL INDUSTRY<br />

Schule has once again supplied table separators type TH3 for the separation of sunflower seeds with this capacity to the new fac-<br />

tory of the customer mironowski in Yerki, ukraine. The table separator is used to separate hulled sunflower seeds from unhulled<br />

seeds. The advantage of this machine over that of other manufacturers lies in the fact that even with extremely varying raw mate-<br />

rial, the residual husk content for the oil presses can be exactly adjusted. Schule has already supplied table separators to three<br />

factories of the company mironowski.<br />

Fig. 1 Table separator Fig. 2 plant mironowski<br />

SCHULE – FOOD TECHNOLOGY<br />

1 2<br />

For more than 100 years, F.H. SCHuLE mühlenbau GmbH have supplied machines, plants, and turnkey factories for the food<br />

industry – worldwide. In past decades, Schule has successfully integrated new fields of activity such as shelling and processing<br />

of cereals, legumes, oilseeds and spices. In the pilot plant at Reinbek near Hamburg, Schule develops new efficient machines and<br />

technologies such as hydrothermal treatment (for example for processing bulgur, quick-cooking products, hygienic treatment, ...)<br />

and protein shifting. Schule offer innovative solutions also in the field of alternate energies production of bioethanol.<br />

32/33


sChulE<br />

BIOETHANOL – HIGHER PR<strong>OF</strong>IT WITHOUT SHELL<br />

Ethanol that has been made exclusively from biomass (renew-<br />

able carbon carriers) or from the biodegradable fractions of<br />

waste products, and which is destined for use as biofuel or for<br />

alcohol production is referred to as bioethanol. Like conven-<br />

tional alcohol, ethanol is obtained by (alcoholic) fermentation<br />

of sugar with the action of microorganisms, and then purified<br />

by thermal separation processes. The raw materials used are<br />

mostly locally available plants with high contents of sugar or<br />

starch: In Europe, these are wheat and sugar beet. Starch-con-<br />

taining raw materials such as cereals are ground. By means of<br />

enzymatic decomposition, starch is converted into sugar dur-<br />

ing liquefaction /saccharification.<br />

nigeria occupies second place in the ranking of the world's<br />

greatest rice importers. The annual rice consumption amounts<br />

to 3.5 million tons, with about 1.5 million tons being imported.<br />

In recent years, it became more and more obvious that nigeria<br />

is highly dependent on rice-exporting countries and has to put<br />

up with a tremendous price volatility on the global market. As a<br />

consequence, the poorest could no longer afford the drastically<br />

increased prices for rice, which caused considerable tension in<br />

the country. On the other hand, nigeria has sufficient arable<br />

land that could be cultivated for rice production, so that the<br />

country might completely abandon the import of rice. Further-<br />

more, due to poor technical standards in the areas of harvest-<br />

ing, drying, storage, and processing in the rice mills, about 30<br />

to 50 % of the local rice harvest is lost every year.<br />

For the future, the government plans a massive promotion of<br />

local rice cultivation and treatment processes by modernising<br />

technical equipment. For this purpose, large-scale promotion<br />

programmes are provided. For more than 50 years, Schule have<br />

supplied parboiling plants and rice mills to nigeria and other Af-<br />

rican countries. At the moment, a turnkey rice processing plant<br />

In the Verticone shelling machines by Schule, wheat or barley<br />

are shelled prior to grinding, which means the outer shell lay-<br />

ers containing only crude fibres (non-fermentable substances)<br />

are removed. As a consequence, the quantity to be treated in<br />

the thermal separation process is reduced so that less energy<br />

is required for cooking, distillation and drying, which increases<br />

the economic efficiency of the process.<br />

In existing plants, in which for example barley with a shelling<br />

degree of about 10 %, is processed, an increase of 10 to 15 % of<br />

the throughput quantity and a higher efficiency can be achieved<br />

by means of pre-shelling.<br />

NIGERIA – PROMOTION AND DEVELOPMENT <strong>OF</strong> AGRICULTURAL RESOURCES<br />

with a parboiling plant and a rice mill is being assembled in<br />

the north of nigeria. When the plant was designed, particular<br />

attention was paid to a sturdy design of the machines and to a<br />

control system that is adapted to the local personnel. Economic<br />

efficiency was an important aspect in the project realisation.<br />

This plant is an important contribution to the promotion of the<br />

rice industry. Technically, the plant is able to convert locally cultivated<br />

paddy rice into rice with a final quality comparable to<br />

that of imported rice – without any loss during processing. The<br />

supply of further plants might help processing the available agricultural<br />

resources more gently so that they may contribute to<br />

achieve food security. At present, further orders for the modernisation<br />

/extension of existing Schule rice processing plants<br />

are being processed and will be completed shortly. With their<br />

experience in the fields of drying, cleaning, and parboiling and<br />

rice milling technology, Schule is an important partner for the<br />

nigerian rice industry.


Fig. 1 Verticone shelling machine<br />

1 2<br />

Fig. 2 parboilingplant<br />

34/35


The die manufacturing area at Amandus Kahl GmbH & Co. KG<br />

has again been expanded. By means of the extension of the<br />

existing die manufacturing building a manufacturing surface of<br />

about 350 m² was added. This new area contains all manufac-<br />

turing machines for turning die bodies. At present, the forged<br />

semi-finished bodies are processed on three vertical lathes.<br />

Additionally, the two existing and well-proven lathes were<br />

equipped with a new control technology. This measure com-<br />

bines the solid mechanical components of the machine with a<br />

very modern CnC technology. As a result, the process flow in<br />

die manufacturing was optimised and the manufacturing ac-<br />

curacy of the dies was improved.<br />

We also invested in a new vertical lathe. On this vertical lathe,<br />

dies up to a diameter of 1600 mm can be received by the hy-<br />

draulically operated power chuck and processed in parallel by<br />

two working units. Two pick-up disk magazine tool-changers<br />

with 16 tool pockets each ensure short tool changing times.<br />

Besides, the machine is equipped with a combined drilling and<br />

milling spindle for drilling holes or milling threaded bores into<br />

the dies. A modern control system provides quick feed motions<br />

and a precise approach of the selected positions. The working<br />

area of the machine is equipped with a solid casing and allows<br />

crane loading from the top or the front.<br />

The investment in three more countersinking and reaming machines<br />

marked another milestone in the modernisation of die<br />

manufacturing facilities. The new machining centres can receive<br />

dies with diameters of up to 1600 mm. The die is processed<br />

by two working spindles which can be used simultaneously. Additionally,<br />

these machines allow other processing methods such<br />

as drilling and thread cutting. An automatic tool changing system<br />

with a total of 32 tool pockets is available for each working<br />

spindle. The machines are completely enclosed and equipped<br />

with an exemplary suction unit. Thus they provide maximum<br />

ease of operation and operational safety for the user.<br />

With the investment in the building and in machinery (investment<br />

volume approx. € 2.5 million), the die manufacturing area<br />

has been remodelled to meet future demands. These measures<br />

/ From our manuFaCTurIng dEparTmEnT<br />

ExPANSION <strong>OF</strong> DIE MANUFACTURING BUILDING<br />

ensure optimised order processing as well as a reduced die manufacturing<br />

time. Furthermore, the use of the new machines<br />

improves the quality of the die geometry.


NEW BENDING MACHINE FOR APPARATUS CONSTRUCTION<br />

The installation of a new bending machine was a major contribution to the modernisation and extension of the sheet metal working<br />

unit. Thanks to the new machine, the efficiency of the entire bending procedure, including programming, the set-up process, and<br />

the actual bending process, has been improved. A safety system ensures quick and precise positioning of the pressure beam and<br />

of the stop fingers. Due to the integrated 4-cylinder drive technology, a compression force of 320 t can be applied to the workpiece<br />

to be bent. The CnC controlled crowning device and the integrated angular position measuring system ensure an accurate bending<br />

result of each workpiece. The short set-up process is facilitated by a visual display and a well designed tool changing system.<br />

AWARD FOR ExEMPLARY VOCATIONAL EDUCATION AND TRAINING<br />

Company-based education and training play an important role in the <strong>KAHL</strong> Group. Currently we employ 40 apprentices, thus the<br />

vocational training attendance rate in our company is about 10 % of the total number of employees. The <strong>KAHL</strong> Group offer both<br />

commercial-technical and industrial-technical training. The professions that can be learned in industrial-technical training are<br />

construction mechanic, cutting machine operator, and mechatronics technician; and industrial business management assistant in<br />

commercial-technical training. We also offer a combined programme of in-company training and university studies in co-operation<br />

with the university of Applied Sciences in Hamburg or with the »nordakademie« in Elmshorn. The degrees that can be obtained<br />

are that of Bachelor of Science in the field of industrial engineering and Bachelor of Engineering in the field of mechanical or<br />

electrical engineering. After a successful completion of the training programme or the studies, the students and apprentices usually<br />

remain employed in the company.<br />

The company Amandus Kahl has been awarded the Apprenticeship Award by the IHK (Chamber of Industry and Commerce) for<br />

exemplary performance in in-company training.<br />

Fig. 1 and Fig. 2 new bending machine for apparatus construction Fig. 3 new die boring machine<br />

36/37<br />

1 2 3


IMPRINT<br />

Publisher:<br />

<strong>KAHL</strong> GRoup<br />

Dieselstraße 5-9<br />

D - 21465 Reinbek<br />

Phone: +49 (0) 40 - 72771 - 0<br />

Fax: +49 (0) 40 - 72771 - 100<br />

www.akahl.de<br />

Edited by:<br />

AMANDuS <strong>KAHL</strong> GmbH & Co. KG<br />

Dieselstrasse 5-9<br />

D - 21465 Reinbek<br />

Phone: +49 (0) 40 - 72771 - 0<br />

Fax: +49 (0) 40 - 72771 - 100<br />

E-mail: info@amandus-kahl-group.de<br />

www.akahl.de<br />

Joachim Behrmann<br />

Jan Behrmann<br />

Bernd Ottlinger<br />

Olaf nährig<br />

Dr. Heinrich Graf von Reichenbach<br />

Dr. Stephan Sternowsky<br />

Philipp Biedenkopf<br />

Sebastian Wache<br />

Dennis Werner<br />

Dr. michael Dolud<br />

Hamid Farahmand<br />

Gabriele Stramm<br />

Erhard Gey<br />

Dr. Werner Sitzmann<br />

michael Gursch<br />

Dr. manfred Heinrich<br />

Fritz A. Kahl<br />

Design & composition:<br />

FARGo<br />

Köhnestrasse 8<br />

D - 20539 Hamburg<br />

Phone : +49 (0) 40 - 79 75 06 78<br />

Fax : +49 (0) 40 - 79 75 06 79<br />

E-mail: info@fargostudios.de<br />

www.fargostudios.de<br />

/ amandus kahl / nEuhaus nEoTEC / F.h. sChulE<br />

NEuHAuS NEotEC Maschinen- und<br />

Anlagenbau GmbH<br />

Dieselstrasse 5-9<br />

D - 21465 Reinbek<br />

Phone: +49 (0) 40 - 72771 - 500<br />

Fax: +49 (0) 40-72771 - 550<br />

www.neuhaus-neotec.de<br />

Silke makoben<br />

Ralf Torenz<br />

Ralf Lippert<br />

Wilhelm mittelstädt<br />

Printing<br />

GK Druck Gerth und Klaas GmbH & Co. KG<br />

Sieker Landstraße 126<br />

D - 22143 Hamburg<br />

Phone : +49 (0) 40 - 675 668 - 0<br />

Fax : +49 (0) 40 - 675 668 - 11 oder -12<br />

E-mail: mail@gkdruck.com<br />

www.gkdruck.com<br />

F.H. SCHuLE<br />

Mühlenbau GmbH<br />

Dieselstrasse 5-9<br />

D - 21465 Reinbek<br />

Phone: +49 (0) 40 - 72771 - 700<br />

Fax: +49 (0) 40 - 72771 - 710<br />

www.schulefood.de<br />

Bernd Kruse<br />

Carl-Ludwig Bollweg<br />

Sylvia Becker<br />

Wolfgang Brümmer<br />

Wulff Schmidt<br />

melanie Forner


<strong>KAHL</strong> GRoup<br />

Dieselstraße 5-9<br />

21465 Reinbek<br />

Phone: +49 (0)40-72771-0<br />

Fax: +49 (0)40-72771-100<br />

info@amandus-kahl-group.de<br />

www.amandus-kahl-group.de<br />

www.akahl.de<br />

www.neuhaus-neotec.de<br />

www.schulefood.de<br />

Worldwide agencies upon request<br />

SuBSIDIARIES<br />

<strong>KAHL</strong> BENELuX<br />

info@amanduskahl.nl<br />

<strong>KAHL</strong> FRANCE<br />

amandus-kahl.france@wanadoo.fr<br />

<strong>KAHL</strong> IBERICA<br />

kahliberica@akahl.es<br />

<strong>KAHL</strong> CAIRo<br />

kahlet@akahlarabic.com<br />

<strong>KAHL</strong> RuSSIA<br />

info@kahl.ru<br />

<strong>KAHL</strong> uSA<br />

info@amanduskahlusa.com

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