A PUBLICATION OF THE KAHL GROUP
/ kahl group 02/03
Dear Business Friend,
We are pleased to inform you on current developments of our Group in this new journal.
Also in this issue of our journal we give priority to innovations within our Group.
To be able to implement the new developments we need you, dear business friend, and
your readiness to tread new paths with the assistance of our employees. After all, the
success of your investment also matters to us. We are particularly proud of having won
the Apprenticeship Award 2009 by the IHK (Chamber of Industry and Commerce) for our
exemplary performance in in-company training. For one thing is certain: The qualification
of our employees is a decisive factor for future success.
Jan Behrmann & Joachim Behrmann
Photo: Hamburger Abendblatt Birgit Jaklitsch / Birgit Schcking.
THE KAHL GROUP
TABLE OF CONTENTS
06 »Kahl reinvents the wheel« 24 Particle technology
08 Large-scale plants for wood pelleting – 25 GmP - Grinders
Plantation Energy Australia
25 Heinen Freezing
09 Residue-free recycling of waste tyres –
From tyres to granulate 25 Sunflower seeds perfectly roasted
10 Recycling of polyethylene terephthalate 27 The perfect espresso
11 Research & Development at Amandus Kahl
29 Enlargement of Premises
12 The sports activities of the Kahl Group
14 Application the flat die pelleting press 14-175 SCHuLE
30 Oilseed processing plant
16 A complete feedmill with innovative for sunflower, soya and rape
technologies in Tatarstan
30 Start-up of a rice mill in Peru
18 Coke dust pellets for steel smelting furnaces
32 High nutritional value of durum wheat (bulgur)
19 Success in the oil palm industry –
32 new ways of oats processing in Belarus
Kahl has taken the first flat die pelleting press for
pellets from empty fruit bunches into operation 33 Precision of separation at 1,000 tons
per day in the oil industry
19 The Crown Expander –
Pelleting without a pelleting press 33 Schule – Food Technology
20 HoweE Eberswalde – 34 Bioethanol – Higher profit without shell
The first pan grinder mill applied in practice
34 nigeria – promotion and development
of agricultural resources
FROm OuR mAnuFACTuRInG DEPARTmEnT
nEuHAuS nEOTEC 36 Expansion of die manufacturing building
21 Finer than fine
37 new bending machine for
22 Energy saving due to preheating of coffee beans
37 Award for exemplary vocational
23 new drum roaster CTR - 3000
education and training
»KAHL REINVENTS THE WHEEL – THE PAN GRINDER MILL!«
our competitors say that the energy consumption of our pel- enough to have fitted through the die holes before! Intriguing,
leting presses is higher as cylindrical pan grinder rollers run isn't it? of course, it is not as easy as that. But this question-
on a circular path and the resulting shearing effect makes our and-answer game led to first trials in the pilot plant and later in
machine an energy guzzler. For decades we have been proving practice – successful tests which raised new questions:
every day that this is not true. partly, we have eliminated this ef-
fect by using conical rollers, mainly in order to achieve a further • Which throughput is reached at which moisture content?
temperature reduction for example during hop pelleting. • Which influence do the input particle sizes G 30 or G 50 have?
• Which are the optimum perforations of the die?
meanwhile we have acted on our competitors' suggestions and • How can the output product be dried?
remembered what pan grinder rollers originally have been used • Can we even do without wet grinding?
for: for crushing various products, mainly grain. Even when driv- • What shall we call this new technology?
en by muscle power pan grinder rollers have been a well-proven • How will the markets react to this new technology?
technology for centuries. But joking aside – also in the recent
past kahl pelleting presses have always had the edge on other
processes when it comes to pelleting fibrous products such as
straw, grass or dried beet pulp. Thanks to the much-maligned
shearing effect, the machine can process also coarse particles
without any problem. The fact that it is used for crushing waste
tyres impressively proves the efficiency of the kahl pelleting
press. nowadays, wood pelleting has gained worldwide accept-
ance. Wood pellets are trading goods and in their quality as a
fuel they definitely compete with oil and gas. as the demand for
pellets increases, the demand for saw dust and wood shavings
increases as well. as an alternative, wood chips can be processed
which, however, have to be crushed in wet condition before dry-
ing. Traditional methods such as knife ring flakers or hammer
mills can be used, yet they have several disadvantages. In fast
running mills there is a tendency to product clogging if the input
product is too wet. Wood chips may have a water content of up
to 50 % and hammer mills have to be aspirated, the exhaust air
being discharged through a filter.
Fast running mills produce sound emissions which are far be-
yond the limit of 85 dba. knife ring flakers, well-proven ma-
chines in the chipboard industry, require regular maintenance
at short intervals. The match-like structures of the product may
cause problems in conveying elements and the downstream pel-
leting plant. Questions often generate ideas: What happens to
wet wood chips in a kahl pelleting press? answer: due to the
high moisture content the pellets will disintegrate. so what? If
the pellets disintegrate, this means that the particles are small View into the pan grinder mill
This new idea aroused immense enthusiasm in our technical nothing now can stop a rapid market relaunch of the pan
and sales departments so that numerous measurements were grinder mill. This »new« machine has been used successfully
carried out in various fields of application and the majority of as a pelleting press all over the world and has been optimised
all open questions could be answered rapidly. The markets' re- throughout decades. The wide-ranging type series covers every
action to this new technology has been more than positive. A capacity requirement. After a demonstration at a trade fair, a
customer in Poland bought the first »pan grinder mill« before large German sawmill cancelled the hammer mill that had al-
the machine had been officially released for sale. Today, this ready been ordered and ordered a pan grinder mill for about
pan grinder mill type 37-850 processes 6 – 7 t/h of G30 wood 20 t/h wood chips G30 instead.
chips. The crushed wood chips are dried to a residual mois-
ture content of approx. 10 % in a drum drier and subsequently We receive inquiries for the new technology from the wood-
they are directly pelleted. Thus, the answer to the question if processing industry almost every day. new complete plants
dry grinding can be dispensed with is yes. Later, this was con- are equipped now with Kahl technology including wet grinding
firmed in our plant at HoWee at Eberswalde. Our live demon- lines of wood chips, the belt drier and pelleting lines.
strations of the pan grinder mill at trade fairs in Stuttgart and
Hanover were a complete success and Kahl was awarded an Amandus Kahl is the only manufacturer to cover such a wide
innovation prize for the pan grinder mill in Stuttgart. range of processes in a modern wood pelleting plant with their
Which advantages does the pan grinder mill have when used for
crushing wood chips? The following arguments are convincing:
• No aspiration is required.
• The sound emissions are below 75 dbA
• Drying of the defibered wood is more economic.
• The fibres produced by the pan grinder mill
ensure an improved pellet quality.
• Dry grinding can be dispensed with if the
die perforation is 6 mm
• High moisture contents do not cause problems but
reduce the specific energy consumption
The capacity of the pan grinder mill is up to 40 t/h
POWERFUL LARGE-SCALE PLANTS
FOR WOOD PELLETING IN AUSTRALIA
In the meantime 2 plants have started production.
Plantation Energy Australia, one of the largest Australian manu- The company with production facilities in Albany, Western Aus-
facturers in the international wood pellets business, has chosen tralia, is managed by an experienced executive team. Further
Amandus Kahl as their exclusive partner for the production of manufacturing capacity is under development in the "Green Tri-
wood pellets. angle" region between Victoria and South Australia. Plantation
Energy Australia has positioned itself as a market leader in the
The plants will produce industrial and high-quality premium pel- production and supply of biofuel.
lets on the basis of eucalyptus and pine wood from local planta-
tions. The central part of every production line is the pelleting
plant with 4 flat die pelleting presses type 60-1250 each - the
flagship among the wood pelleting presses. With its sturdy de-
sign and a drive power of 2 x 200 kW, this pelleting press is the
most suited machine for the high demands arising from these
enormous production capacities. Plantation Energy is based in
Western Australia with offices in melbourne and Perth and is
funded by Denham Capital, a leading private equity firm in the
energy sector operating world-wide.
ENVIRONMENTALLY FRIENDLY AND RESIDUE-FREE RECYCLING OF WASTE
TYRES FROM TYRES TO THE GRANULATE IN ONLY 2 STEPS
For more than 10 years, the kahl technology has been well 1
known in waste tyre recycling. The convincing technology of
granulation using flat die pelleting presses has established itself
in the market. With the foundation of the public recycling as-
sociation signus Ecovalor in may 2005, spain introduced com-
prehensive legal provisions for tyre recycling. The plant supplied
to our customer in the north-east of madrid (annual capacity
30,000 t of waste tyres) is based on a design with a two-stage
grinding plant and has been started-up in record time. The pro-
duced granulates are to be used for sports venues surfaces, im-
pact protection devices and for road construction. In the united
arab Emirates, tyres used to be disposed to an ever-expanding
landfill (20 million tyres) outside the city limits for decades. The
company Emirates recycling llC, a member of the al rostamani
group, charged amandus kahl with the construction of the larg-
est waste tyre plant to date with an input capacity of 10 t/h.
another plant made by kahl was put into operation in north-
ern greece in the year 2009. Close to the border with Bulgaria,
a waste tyre recycling plant with a capacity of 15,000 tons per
year was built. The kahl technology has also been convincing
in our neighbouring country austria. In 2009, the granulators
and cutting mills in austria's largest waste tyre recycling plant
were dismantled and two new granulation lines equipped with
kahl pelleting presses of the type 60-1500 were erected. This
exchange allows the production of granulate in only two crush-
Figure 1 – 2 granulation plant, spain
RECYCLING OF POLYETHYLENE TEREPHTHALATE (ABBREVIATION PET)
The development of the process for PET recycling has been underway for more than 2 years now. In cooperation with the
company LCI, the Amandus Kahl representation in the uSA in the field of chemistry, and a well-known u.S. company, a proc-
ess was developed that allows the production of a granulate from shredded PET bottles which can be directly reused for the
production of PET bottles. Since the newly developed process is very sensitive, it was necessary to adapt the corresponding
machines to the process. The process functions with very short effective bores at relatively high temperatures (about 130 °C);
thus the machines have to be operated with oil cooling and special lubricants as well as with special devices. The development
is based on the pelleting press type 33-390 the data of which was used to design the current production presses type 38-600.
Since the beginning of 2009, two plants have been put into operation,
which achieved the calculated expectations of quality and quantity right from the start.
RESEARCH & DEVELOPMENT AT AMANDUS KAHL
In the highly dynamic environment of a medium-sized company The ideas and developments are the result of the cooperation
with a vast field of activities, the classical department of re- of many departments and of the interaction with institutions,
search & development (R&D) has to be open-minded and flex- our customers, prospective buyers and associates of our com-
ible in order to meet the high demands of our customers with pany. The development is never completed when the first ma-
regard to innovations in process engineering and plant and me- chine is fabricated or the first process is implemented. These
chanical engineering. innovations are always accompanied by the staff of our R & D
department or the pilot plant who assist our customers during
The success in recent years, and in fact for decades, proves that start-up and production.
the company's high investments in the field of R & D and in
the pilot plant have been justified. Our philosophy in research
and development is to advance the well-known main machines
such as flat die pelleting press, expander, belt drier, etc. and
to modify and optimise them for new markets and processes
so that they can be used also in new and yet to be discovered
In the following some examples of the adaptation of such plants
to new industrial sectors:
• Grinding concepts for cereals for the production of bioethanol
• Optimisation of the pelleting presses for wood pelleting
• Shaping of distillers grains (bioethanol)
• Extruder in the semi-luxury items industry
• Pan grinder mill for grinding (article in this Journal)
• Fabric belt drier
• Crown Expander
Other examples of process engineering solutions with optimum
adaptations of the machines:
• Extruder (on the basis of the expander) => fish feed plants
• Pelleting press 1500
• Flat die pelleting press in the pharmaceutical sector
• Continuous cooker / vacuum coater
• Waste tyre recycling plants
• Batch mixer for preheating of green coffee
THE SPORTS ACTIVITIES OF THE KAHL GROUP
It started about 10 years ago: Our former works manager, mr. 1
Gallus, had infected some of his colleagues with his enthusiasm
for bicycle racing: They signed up for the HEW Cyclassics as the
event was called back then, a cycling classic held in Hamburg
every year. They started training together in spring and divided
into several »KAHL teams« competing over the distances of 50
km, 100 km or 150 km. This enthusiasm has grown every year;
nowadays the participation in the Cyclassics has become a tra-
dition in the company Kahl with a steadily increasing number
of participants (unfortunately, only one female colleague has
taken part in the race, so far). Even some of our agents from
abroad let themselves be infected with our enthusiasm, for ex-
ample mr. Götti from Switzerland and mr. Codega from Italy.
We always appreciate their support!
In 2009, four colleagues put the icing on the cake with an
extraordinary performance: They took part in the »Vättern-
rundan«, a non-stop (!!!) 300 km bicycle ride around the lake
Vättern in Sweden. not only the 300 km ride is a fabulous per-
Fig. 1 "magic dribblers" in action
formance – also braving the weather is a real challenge: Wind,
Fig. 2–4 our team of cyclists is remarkably successful every year
rain, 9 °C. All four colleagues crossed the finishing line safe and
» Sport keeps you young -
Cycling was not to remain the only activity. Some years ago,
our football players decided that they wanted an opportunity
that is his motto - and he himself is
to play a match »within the company«: now, it has become a the best proof of it! «
tradition to arrange a football tournament with subsequent
barbecue right before the summer holiday every year. The last
tournament was won by the team of our managing director
mr. Joachim Behrmann (70) who never fails to take part. Sport
keeps you young – that is his motto – and he himself is the best
proof of it! Those colleagues who prefer moving their brains
to moving their legs have started yet another tradition: Every
year, we arrange a skat tournament (a card game passionately
played in Germany) which has become so popular that even our
retirees enter the date in their diaries well in advance.
THE FLAT DIE PELLETING PRESS 14-175
IN GMP/FDA CONFORMING DESIGN
Due to the increase of the world population and the higher life The goals of granulation are:
expectancy combined with the desire for a better quality of life, • No segregation of the individual components
the pharmaceutical industry holds a good position in the mar- • Improved flowability
ket. The high demand for drugs earned the pharmaceutical en- • Improved proportioning accuracy due to small granules
terprises high sales and profits. Apart from the drug discovery, • Good tabletability
the pharmaceutical enterprises have to attach great importance • Modification of properties in the tablet (for example
to optimising their production processes to meet the demand increase of abrasion resistance and improvement of
for low costs. Yet, the possibilities for cost reduction are limited. decomposition characteristics)
The production costs account for a significant proportion of the mainly, we distinguish between two process variants in the
total costs. In connection with optimisation measures, flexibil- production of granules:
ity and automation are important tools for cost reduction. Also • Moist granulation
alternative processes or new machines – even from outside the • Dry granulation / melt extrusion.
industry but well-proven ones, are discussed. All plant compo-
nents, however, have to conform to the high requirements on moist granulation (i.e. of a powder mixed with water or a
hygienic standards. This includes also constructional features water-binder solution) is realised for example with:
such as the absence of dead space, electropolished surfaces, • Fluid bed agglomerators
or validated cleaning concepts. They have to conform to GmP • High shear-intensity mixers (batchwise).
(Good manufacturing Practice) and FDA (Food and Drug Admin- • Extruders (continuously).
The following description of the process of agglomeration by However, drying of the wet granules is required. Drying is usu-
compression using flat die pelleting presses explains the ad- ally realised batchwise in the fluid bed (-> see page 24 - Particle
vantages of this process over traditional processes as well as Technology).
the experience with the production of granules gained in this
industry, so far. Basically, granules are preparations that con- The extrusion process is also a proven technology for the com-
sist of solid and dry grains, each grain being an agglomerate of paction of bulk products. In the pharmaceutical sector, for ex-
powder particles with a sufficient stability to allow for differ- ample twin-screw extruders with subsequent spheronisation
ent manipulations. Granules contain one or more active agent. are used. Due to the cost constraints mentioned above, ma-
They can either be used directly as drugs or as an intermediate chines for agglomeration by compression can be considered.
product for the production of other dosage forms such as cap- Apart from roller compactors (production of oblong strands or
sules or tablets. The granulation of powdery tablet masses is a flakes), also extrusion presses or flat die pelleting presses can
common and necessary process. be used. For this purpose, Amandus Kahl GmbH & Co. KG has
further developed the well-known laboratory machine 14-175.
Fig. 1 pelleting press type 14-175 Fig.2 pelleting elements pan grinder rollers and die
For many years, the flat die pelleting press has been successfully used for granulation /compaction in the pharmaceutical indus-
try- also on a production scale. It offers important advantages. The latest generation of the flat die pelleting press 14-175 in GmP
/ FDA conforming design has not only been advanced constructionally. Its process technology has also been examined in other
pharmaceutical applications. This press type was extensively examined at the Faculty of Pharmaceutical Technology at the univer-
sity of Düsseldorf (Prof. Kleinebudde) with regard to moist extrusion and melt extrusion processes. The flat die pelleting press was
declared an appropriate machine for pharmaceutical applications. It was also used successfully for processing lipid formulations in
a research project of the university of Düsseldorf. The compression or extrusion of the lipids was realised under pressure and at a
temperature below the melting temperature of the lipids (thermomechanical process). The decisive advantage over melt extrusion
lies in the fact that the lipids are treated gently and thus the lipid structure largely remains intact.
A COMPLETE FEEDMILL WITH INNOVATIVE
TECHNOLOGIES IN TATARSTAN
The feed plant was designed by Amandus Kahl with the main 1
machines being of their supply. The entire plant was built in the
record time of one and a half years and has been designed as
a seven-storey building with a height of 40 meters. 24 silos for
raw materials and 24 silos for finished products are available.
The silos are 19 m high, have a diameter of 2.5 m and a volume
of 95 m³ (Fig. 1).
The automated production line achieves a capacity of about
20 t/h of finished product. The innovative batch system allows
for rapid formula change. The raw materials are proportioned
into the batch weigher and ground using the hammer mill
(Fig. 3). The ground mixture is either fed into the plant for fin-
ished products or into the pelleting line with expander. This pel-
leting and/or expansion process is automated and commences
with the mixture of the crushed raw materials in a mixing con-
ditioner (Fig. 1).
Feedstuff for all species of production animals of differing ages
and for different production targets are produced. mash feed,
crumbles (pellets), expanded feed or structurised expanded Fig. 1 The factory has a capacity of 20 t/h
feed can be produced. Expandat® is produced with an annular Fig. 2 – 3 pelleting press and hammer mill
gap expander. Expandat® is a compound feed which has been Fig. 4 annular gap expander, Fig. 5 Conditioner mk, Fig. 6 Belt drier
exposed to hydrothermal treatment by the expander (Fig. 4) and
which has been produced as a granulate, without pelleting.
The specialists of the feedmill can individually optimise the
feed formulae according to the customer's demands. This op-
timisation will not only take into account the age, but also the
performance as well as the husbandry method of the animals.
Furthermore, the customer's production targets are observed
by optimising the feed rations. If needed, the specialists of the
feedmill visit their customers in their factories in order to ana-
lyze and solve problems on site.
ASIA: COKE DUST PELLETS FOR STEEL SMELTING FURNACES
The pellets are fed into blast furnaces for steel production. 1
Acting as a service contractor of the major Asian steel manu-
facturer, our customer processes coke dust from the filters
of coke lines. The coke dust is provided free of charge. The
value of the pellets might correspond to that of coke which
has varied between $ 190.00, and 680.00 $ in recent years.
Our customer imports mainly coking coal for his own coking
plants, to a certain extent he also imports ready made coke.
The aim is to reduce the coke import and to optimise his
own coke production process in order improve the quality
of the produced coke. This includes a more efficient use of
the dust produced in the coking plants.
Fig. 1 pelleting press type 39-1000
At present 8 pelleting lines equipped with pelleting presses
type 39-1000 are in operation. Their throughput capacity
is 5 – 6 t/h each. Pellets with a diameter of 4.5 mm are
Coke dust pellets meet two important goals. First, full-value
coke is obtained and the dusts do not have to be sold be-
low their value - after all, the dusts have caused high cost
for raw material, transport and the coking process. Second,
due to their homogeneity, the pellets have a defined sink-
ing behaviour in the blast furnace, which improves the steel
Fig. 2 Empty fruit bunches (l.) and biomass pellets (/r.)
Fig. 3 Crown expander
SUCCESS IN THE OIL PALM INDUSTRY -
KAHL HAS TAKEN THE SECOND FLAT DIE PELLETING PRESS FOR
PELLETS FROM EMPTY FRUIT BUNCHES INTO OPERATION
In 2009, the first flat die pelleting press for the production of biomass pellets from Empty Fruit Bunches was put in operation in
malaysia. meanwhile our customer successfully commissioned the second pelleting press type 45-1250 for Empty Fruit Bunches - a
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
production and for refinement into ethanol in the BTL process. With pelleting plants for oil palm fronds, Amandus Kahl has already
gained an excellent reputation in malaysia and regularly delivers pelleting presses to that country. EFBs have been the centre of
interest of the biomass industry for some time as large quantities of EFBs are produced as a residue in palm oil mills, which means
that they do not produce any transport costs for raw material supply. The largest producers of palm oil are malaysia and Indonesia.
Palm oil is also produced in Africa, South America and other Southeast Asian countries.
THE CROWN ExPANDER: PELLETING WITHOUT A PELLETING PRESS
Our customers operate more than 600 expanders worldwide. strands leaving the die to uniform pellet lengths. So the »Crown
In the u.S.A. for example, turkey fattening feed is expanded Expander« was born. The machine owes its name to the crown
before pelleting in most cases. The annular gap expander has form of the first dies which were provided with slits instead of
proved to be a good solution also in other fields such as starch bores.
modification or the oilseeds-processing industry. And last but
not least, we have developed our Kahl extruder on the basis One important component of the annular gap expander re-
of the expander. With the extruder even higher mechanical mained unchanged in the Crown expander: The hydraulically
energy inputs and modification degrees can be realised, and moveable cone. This cone can be moved into and out of the
the products – fish feed, petfood, and snacks – can be pelleted crown die at the outlet end. Depending on the position of the
or given other defined shapes. For quite some time, there has cone in the die, more or less die bores are open for the produc-
been a clear tendency towards coarse grinding of feed. tion of pellets. Thus the pelleting process is easy to control by
simply varying the cone position – in contrast to conventional
Amandus Kahl remembered that in the annular gap expander, extrusion processes which require die changes or far more
coarse grinding structures remain largely unchanged, although complicated control mechanisms.
the product is exposed to a strong pressure and kneading ef-
fect. The pressure load in the expander acts on all sides of the The results obtained so far, have met every expectation, which
coarse particles. The homogeneous pressure distribution on means that we succeeded in the proverbial »squaring of the cir-
the entire particle circumference is supported by embedding cle«: The Crown expander produces pellets or other regularly
these coarse particles in a pasty moist matrix of fine particles. shaped structures while preserving coarse particles and simul-
Another advantage lies in the fact that the finer particles are taneously agglomerating fine and finest components. The posi-
agglomerated during expansion and thus are transformed into tive nutritional effect of expansion is an additional advantage
coarse structures. It occurred to our engineers that they might which traditional pelleting does not offer.
equip the expander outlet with an annular die similar to that of
a pelleting press. A die without pan grinder rollers to be more
precise, as they wondered: Should the high internal pressure The crown expander – an ideal example of a successful further
of the expander not be able to press the finished product right development taking into account aspects of animal nutrition
through the round or oblong bores in the die ring, thus making and process technology.
the pressing and crushing effect of pan grinder rollers superflu-
ous? – A rotating cutter was designed, meant to cut the product
HOWEE EBERSWALDE – THE FIRST PAN GRINDER MILL APPLIED IN PRACTICE
For years, the wood pelleting plant of the company HoweE near the drier. Both devices provide a product with excellent convey-
Eberswalde (north of Berlin) has worked perfectly. The main ing and pelleting properties. About 165 tons of DIn Plus pellets
components of this plant are a belt drier with a length of 40 are produced in this plant with three pelleting presses in three-
m and three pelleting presses type 39-1000. The KAHL scope shift operation every day.
of supply includes the belt drier with prebin, the silo for dried
wood chips, the pelleting and cooling plant as well as the load-
ing silos. The plant has been designed for a capacity of 7.5 t/h
of pellets in its final construction stage. A special feature of the
plant is the fact that there is no dry grinding unit. A chopper
and a pan grinder mill type 45-1250 are arranged upstream of
View into the pellet production plant
FINER THAN FINE
ultrafine coffee grinding is a technology that requires a lot 1
of know-how and precision. neuhaus neotec roll grinders set
technical standards for this type of grinding.
For the preparation of Turkish mocca for example, the roasted
coffee is crushed to an almost floury fineness. ultrafine grind-
ing takes it one step further – the roasted coffee is very finely
ground so that there is no granular structure to be felt when
rubbing the ground coffee between the fingers – it is simply
With more than 40 years of experience in coffee grinding, neu-
haus neotec offer roll grinders that represent state-of-the-art
technology. The particle size of ultrafine grinding is approx. 50
µm, with the gap width between the special rolls being below
10 µ. With this process, a particularly fine and homogeneous
ground product can be produced thanks to special roll drives
and high-capacity cooling during the grinding process.
A touch screen control system and a sensitive temperature
monitoring system facilitate the control of the grinders. The
special roll geometry and surface design in combination with
separate drives ensure an extremely precise adjustment of
the grinding degree. Furthermore, built-ups which can occur
when grinding fine coffee, can be overcome by using a dynamic Fig. 1 roll grinder Wms
Different sizes of the neuhaus neotec roller mills for ultrafine
grinding with capacities ranging from 100 to 1000 kg per hour
Fig. 2 superfine coffee
/ nEuhaus nEoTEC
ENERGY SAVING DUE TO PREHEATING OF COFFEE BEANS
In times of high raw material and energy costs, coffee roasters do not only have to consider the quality of their roasting processes;
they also have to optimise these processes in terms of energy savings and cost reduction.
An efficient way to save energy is preheating of the green coffee, which further optimises the already energy-efficient neuhaus
neotec roasting plants.
This is the functional principle of green coffee preheating: Prior to the actual roasting process, the green coffee batch is preheated
to a temperature of about 100 °C in a preheating chamber before it is fed into the roasting chamber. The thermal energy stored in
the beans can not only shorten the subsequent roasting process but also reduce the quantity of consumed energy during roasting,
which in turn causes a reduction of CO2 emissions. neuhaus neotec offer two different systems which reduce energy costs by up
to 25 % and CO2 emissions by about a quarter. Preheating does not only reduce costs and emissions, it also increases the capacity
of the roasting machines by up to 20 %.
green coffee preheating in a coffee roasting plant in southern germany
THE NEW DRUM ROASTER CTR - 3000
neuhaus neotec complement their range of products by a roasting machine for traditional speciality roasting.
The roasting plants of neuhaus neotec stand for an innovative and progressive convection roasting technique. About 20 years ago,
the introduction of the RFB roaster covering the entire range of roasting times and qualities laid the foundations of the internation-
al success of the roasting plant manufacturer. For the traditional recipes of speciality roasters, neuhaus neotec now complement
their range of products by a new drum roaster that has been tailor-made for longer roasting times and classical roasting concepts.
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-
ties are also available. Even though the drum roaster is especially suited for traditional roasts, it also offers new technical solutions,
high-quality safety technology and a modern energy concept. With the new CTR - 3000, neuhaus neotec can provide also those
roasting plants with complete lines which favour the drum roaster. Thus they profit from neuhaus neotec's well-known compe-
tence as well as from considerably easier and more reliable planning, installation and start-up. meanwhile, the first CTR has started
production in a major German roasting plant. now it works round-the-clock to the customer's complete satisfaction.
/ nEuhaus nEoTEC
With the establishment of the new department »PARTICLE For this reason the department »Particle Technology« of neu-
TECHnOLOGY« neuhaus neotec has set the course for a suc- haus neotec maschinen- und Anlagenbau GmbH has developed
cessful future. With our process-oriented research we open up a new continuous fluidised bed pilot plant for the capacity
fields of application not only in the coffee industry but also in range of 5 to – 50 kg/h, with which an upscale is possible with-
the pharmaceutical, chemical, and food and semi-luxury items out difficulties due to the flexible plant configuration and on
industry. In doing so we profit from synergy effects with the the basis of a long-standing know-how.
KAHL Group. In may 2009, we presented ourselves jointly for
the first time on the occasion of the world's largest trade fair for The outstanding feature of this modular and thus mobile
process engineering, the ACHEmA in Frankfurt. plant is an exchangeable product bin which is designed indi-
vidually for the different processes, such as drying, agglom-
The core competence of the new department are continuous eration and spray granulation, and which covers different ca-
fluidized bed processes and roller mills for low-dust grinding. pacity ranges due to variation of the distribution plate. The
Fluidized bed processes are efficient and due to the intensive plant is installed in the GmP area of the pilot plant building
exchange of heat and material they are the first choice if ther- and has been available for tests since the beginning of 2010.
mal treatment of bulk products (drying and cooling) and the
formation of particles from powders (agglomeration) or liquids
(spray granulation) are concerned. Top and bottom spraying
processes in the fluidized bed have gained acceptance for the
production of instant products and granulates for subsequent
compaction, for example. There is no reason not to use continu-
ous processes (reproducible, fully automatic, product quality).
Even for capacity ranges of 10 kg/h and less this process has
been applied successfully in the pharmaceutical industry, since
a better understanding and control of the process are possible
due to the constant conditions.
pilot plant 20/4
GMP-GRINDER HEINEN FREEzING
Our roller mills are used for applications in the chemical, min- The Heinen Freezing GmbH has more than 25 years of experi-
eral and metal industry, in the food industry and in the pharma- ence with regard to the process steps of pasteurization, freez-
ceutical industry. ing, cooling and conditioning in industrial food processing.
Since January 1, 2010 the KAHL Group has held a majority of
The well-established laboratory grinder LWm 100 has been de- shares in this company.
veloped and improved especially for demanding applications
in the pharmaceutical and chemical industry or in the food in-
dustry. The new design with drive system and control elements
housed together in one stainless steel case allows quick and
easy cleaning. All product-contacting parts are designed in
stainless steel 1.4404 (316 L) with a surface quality of < 0.8 µm.
gmp conforming roller mill type lWm - 100 neuhaus neotec continues the brand »heinen drying«
since the beginning of 2010
/ nEuhaus nEoTEC
SUNFLOWER SEEDS PERFECTLY ROASTED
In Eastern Europe, roasted sunflower seeds are a popular »in between« snack. With the rg roasters of neuhaus neotec these treats
can be processed without problems.
Flexibility and simple operation are two characteristics that define the rg specialty roasters of neuhaus neotec. But these attributes
do not only relate to the roasting of coffee beans. also other products, such as sunflower seeds, pumpkin kernels, nuts and Chicory
can excellently be processed with the innovative and flexible hot-air roasting technology of the neuhaus neotec roasters. recently
the fourth project for an rg roaster for sunflower seeds could be completed in Eastern Europe. The rg 100 and rg 150 roasting
machines are designed to roast 1000 or 1500 kg per hour.
roasting is realized exclusively in a rotating motion in the hot-air current. This process and the excellent mixture provide uniform
roasting of the product. The simple design of the plant, without mobile parts in the roasting or cooling chamber, ensures low main-
THE PERFECT ESPRESSO
neuhaus neotec has proved over and over again that the tried
and tested rFB (rotating Flexible Batch) roasting system meets
the most varied requirements. not only does this process com-
bine maximum production consistency with low energy con-
sumption and maintenance requirements – rFB roasters also
stand out due to their flexibility covering the whole range of
In particular, the very short response times, which the system
owes to the low heat capacity of the roasting chamber, enable
advanced methods of exerting influence on the roasting process
to be applied, such as profile roasting and copy roasting – pro-
cesses which were developed and tried by neuhaus neotec a
long time ago.
Today, many big coffee roasters prefer the rFB especially for
their espresso roasts. The low air temperature and gentle pro-
duct treatment ensure a result that is second to none. as es-
presso market requires varied nuances of flavour, the rFB is
the appropriate machine when it comes to producing perfect
Capacities for espresso roasting: up to 4 t/h.
/ nEuhaus nEoTEC
Advanced technology with a spectacular architecture flexibility and redundancy in five grinders and have to be rapidly
packed. now he has every reason to be satisfied with himself
In summer 2009, one of the largest newly built coffee roasting and his staff. meanwhile, the factory produces more than a
plants in the world started operation in Helsinki, Finland. neu- hundred million coffee packs per year.
haus neotec supplied almost the complete logistics and techno-
logy for the new roasting plant of Gustav Paulig Ltd.
In summer 2009, the largest roasting plant that had been built DAtA oN tHE RoAStING FACtoRy
worldwide in that year started operation. The coffee roasting
area: approx. 32,000 m²
plant is located in the Vuosaari Harbour in the Finnish capital
Volume: approx. 345,000 m3
Helsinki and produces up to 5 tons of roast coffee per hour. This
length x width: approx. 300 x 150 m2
was a huge project which required not only the construction of
highest point: approx. 40 m
one of the largest roasting plants in the world but also the in-
tegration of individual lines of the former Paulig roasting plant lowest point: approx. 12 m
in Finland.The interior of the roasting plant as well as the silo
building was planned and constructed by the German company - green coffee receiving and storage
neuhaus neotec which planned and supplied the entire logis- - Coffee roasting process
tics and technology from the green coffee receiving facilities to - Coffee grinding process and transport
the packing lines with the exception of the roasting machines. - packing and palleting
Project manager Wilhelm mittelstädt of neuhaus neotec refers - storage unit
to the construction of the new roasting plant as »one of the - Control room
biggest projects I have ever planned and realised«. The prepara- - storage for mechanical equipment
tory works of this construction project lasted several years. The - production offices
actual cooperation for the project began with the submission Total investment: approx. 120 million Euro
of a first offer in summer 2006. Three years later, the major
part of the new roasting factory was finished and could be put
into operation. until the end of September, the new roasting
plant already exceeded the roasting capacity of the former Pau-
lig roasting plant in Finland. The main packing lines for ground
coffee, for example, have a capacity of four tons per hour. Five
large grinders crush the roasted beans. In total, there are 45
silos for the storage of ground coffee.
Paulig divided the project into three process sections: (1) the
green coffee process (receiving, quality control, storage, and
blending), (2) the roasted coffee process and (3) the ground
coffee process including packing. The project manager charac-
terizes the ground coffee transport as the most complicated
task of the entire construction of the new plant. The complexity
of the task consisted of planning and achieving a line capaci-
ty of five tons of coffee per hour which are ground with high
ENLARGEMENT OF PREMISES
1 For some months now, the 105 employees of nEuHAuS nEOTEC
do not only have had more workspace, but also a new pilot plant
where the two most important fields of activity – coffee proces-
sing and particle technology – are united under one roof.
Apart from a new generous entrance area, the ground floor of
the annexe building mainly accommodates the central part, i.e.
the new pilot plant with a surface of about 400 m². Enough
space for the research and development department where
plants and installations are tested according to the customers'
demands and adapted to the customers' products. These cus-
tomers are mainly companies from the food and semi-luxury
items industry and the chemical and pharmaceutical industry.
Fig. 1 Conveying plant for ground coffee at paulig
The upper floor has a surface of 500 m² for new offices and
modern conference rooms.
Thanks to the the seven-digit investment in the annexe building
the managing director mr. Gustav Lührs considers the location
Ganderkesee to be well prepared for future orders and projects.
Should nEuHAuS nEOTEC ever be running out of space in the
industrial area Hoykenkamp (Ganderkesee), the foundation for
a further extension will already have been laid - as the construc-
tion of another storey is possible at any time.
Fig. 2 Conveyor for ground coffee at paulig
new building with pilot plant at ganderkesee
COMPETENCE IN THE FIELD OF EDIBLE OIL
OILSEED PROCESSING PLANT FOR SUNFLOWER, SOYA AND RAPE
Recently, a combined sunflower, soybean and rapeseed oil mill a capacity of 12 t/h. The process steps include cleaning, grad-
has been put into operation. The Schule scope of supply com- ing, and flaking upstream of the oil press. using the innovative
prises the entire conditioning unit including the oil-press as Schule process and high-quality machines all the customers' re-
well as the fully automatic control system of the plant. quirements could be exceeded.
The respective products are processed in the plant with the The process ensures a controlled crude fibre content (protein
following process steps and throughputs: Sunflowers are proc- content) of the extraction meal varying as required, as well as a
essed at a capacity of about 15 t/h. The process steps include minimal residual grain content in the shells/husks.
cleaning, grading, husking, separation of husks, sorting with
variably adjustable residual husk content in the husked grain
fraction, and flaking upstream of the oil press. Soybeans are
processed at a capacity of about 10 t/h. The process steps in-
clude cleaning, grading, granulation, separation of husks on de-
mand, and flaking before oil extraction. Rape is processed with
START-UP OF A RICE MILL IN PERU
In September, a rice mill (shelling, whitening, polishing, and col- shelling degree of more than 95 % was achieved. Because of
our sorting) with a capacity of 15 t/h, equipped with machines the nature of the raw material processed in Peru, characterised
of the company Schule was started up in Peru. A new whiten- by a high degree of impurities (chalky), and the high demands
ing technology is used in this mill. This innovative process is of the local market, the colour sorting machine DCD 320 was
realised by means of the Verticone (VPC). Due to the flexibility integrated into the plant.
and ease of operation of this machine, rapid optimisation of
the process is possible, both for changing the types of rice to
be processed and for varying quality requirements on the final
product. Another advantage of the machine is its low energy
consumption. Currently, the Verticone VPC 480 is the shelling
machine with the highest capacity on the market.
The polishing machine RPm 2A with the round screen basket,
newly developed by the company Schule, is also used in the
mill. With the use of this screen basket a uniform and improved
polishing effect is achieved. The new shelling machine SHA has
proven its high capacity when shelling tropical paddy. Although
tropical paddy is difficult to shell, a capacity of 5 t/h with a
Fig. 1 air sifter at ulerum
Fig. 2 View into the new rice mill in peru Fig. 3 plant ulerum
HIGH NUTRITIONAL VALUE OF NEW WAYS OF OATS PROCESSING
DURUM WHEAT (BULGUR) IN BELARUS
Due to its durability, its good storage and flow properties as well Schule received the order for the modernisation of an exist-
as its high nutritional value and easy preparation, bulgur has ing oat mill and the installation of a quick-cooking and groat-
met with great interest in many parts of the world. In compari- ing plant on the basis of the new continuous pressure-cooking
son with other wheat products bulgur belongs to the nutrition- process by Schule. After the implementation of this project
ally most valuable dishes. Bulgur is produced by means of soak- the customer achieved a significant increase in quality of the
ing, continuous cooking and drying with subsequent husking final product. The new Schule steaming and cooking process
and groating of the durum wheat. Recently, the company Schule is energy-saving and thus increases the economic efficiency of
has successfully started up a complete plant for the production the plant.
of bulgur for the company Al-Gurair in Dubai.
1. Scope of supply of the oat processing plant – It consists of the
groups: Cleaning, husking, cutting, and control system
2. Scope of supply of the continuous quick-cooking plant –
It consists of the groups: Preparation, cooking, drying and
Fig. 1 Bulgur plant in the united arab Emirates
Fig. 2 Belt cooker during start-up Fig. 3 Belt cooker in our pilot plant
PRECISION OF SEPARATION AT 1,000 TONS PER DAY IN THE OIL INDUSTRY
Schule has once again supplied table separators type TH3 for the separation of sunflower seeds with this capacity to the new fac-
tory of the customer mironowski in Yerki, ukraine. The table separator is used to separate hulled sunflower seeds from unhulled
seeds. The advantage of this machine over that of other manufacturers lies in the fact that even with extremely varying raw mate-
rial, the residual husk content for the oil presses can be exactly adjusted. Schule has already supplied table separators to three
factories of the company mironowski.
Fig. 1 Table separator Fig. 2 plant mironowski
SCHULE – FOOD TECHNOLOGY
For more than 100 years, F.H. SCHuLE mühlenbau GmbH have supplied machines, plants, and turnkey factories for the food
industry – worldwide. In past decades, Schule has successfully integrated new fields of activity such as shelling and processing
of cereals, legumes, oilseeds and spices. In the pilot plant at Reinbek near Hamburg, Schule develops new efficient machines and
technologies such as hydrothermal treatment (for example for processing bulgur, quick-cooking products, hygienic treatment, ...)
and protein shifting. Schule offer innovative solutions also in the field of alternate energies production of bioethanol.
BIOETHANOL – HIGHER PROFIT WITHOUT SHELL
Ethanol that has been made exclusively from biomass (renew- In the Verticone shelling machines by Schule, wheat or barley
able carbon carriers) or from the biodegradable fractions of are shelled prior to grinding, which means the outer shell lay-
waste products, and which is destined for use as biofuel or for ers containing only crude fibres (non-fermentable substances)
alcohol production is referred to as bioethanol. Like conven- are removed. As a consequence, the quantity to be treated in
tional alcohol, ethanol is obtained by (alcoholic) fermentation the thermal separation process is reduced so that less energy
of sugar with the action of microorganisms, and then purified is required for cooking, distillation and drying, which increases
by thermal separation processes. The raw materials used are the economic efficiency of the process.
mostly locally available plants with high contents of sugar or
starch: In Europe, these are wheat and sugar beet. Starch-con- In existing plants, in which for example barley with a shelling
taining raw materials such as cereals are ground. By means of degree of about 10 %, is processed, an increase of 10 to 15 % of
enzymatic decomposition, starch is converted into sugar dur- the throughput quantity and a higher efficiency can be achieved
ing liquefaction /saccharification. by means of pre-shelling.
NIGERIA – PROMOTION AND DEVELOPMENT OF AGRICULTURAL RESOURCES
nigeria occupies second place in the ranking of the world's with a parboiling plant and a rice mill is being assembled in
greatest rice importers. The annual rice consumption amounts the north of nigeria. When the plant was designed, particular
to 3.5 million tons, with about 1.5 million tons being imported. attention was paid to a sturdy design of the machines and to a
In recent years, it became more and more obvious that nigeria control system that is adapted to the local personnel. Economic
is highly dependent on rice-exporting countries and has to put efficiency was an important aspect in the project realisation.
up with a tremendous price volatility on the global market. As a
consequence, the poorest could no longer afford the drastically This plant is an important contribution to the promotion of the
increased prices for rice, which caused considerable tension in rice industry. Technically, the plant is able to convert locally cul-
the country. On the other hand, nigeria has sufficient arable tivated paddy rice into rice with a final quality comparable to
land that could be cultivated for rice production, so that the that of imported rice – without any loss during processing. The
country might completely abandon the import of rice. Further- supply of further plants might help processing the available ag-
more, due to poor technical standards in the areas of harvest- ricultural resources more gently so that they may contribute to
ing, drying, storage, and processing in the rice mills, about 30 achieve food security. At present, further orders for the mod-
to 50 % of the local rice harvest is lost every year. ernisation /extension of existing Schule rice processing plants
are being processed and will be completed shortly. With their
For the future, the government plans a massive promotion of experience in the fields of drying, cleaning, and parboiling and
local rice cultivation and treatment processes by modernising rice milling technology, Schule is an important partner for the
technical equipment. For this purpose, large-scale promotion nigerian rice industry.
programmes are provided. For more than 50 years, Schule have
supplied parboiling plants and rice mills to nigeria and other Af-
rican countries. At the moment, a turnkey rice processing plant
Fig. 2 parboilingplant
Fig. 1 Verticone shelling machine
/ From our manuFaCTurIng dEparTmEnT
ExPANSION OF DIE MANUFACTURING BUILDING
The die manufacturing area at Amandus Kahl GmbH & Co. KG ensure optimised order processing as well as a reduced die ma-
has again been expanded. By means of the extension of the nufacturing time. Furthermore, the use of the new machines
existing die manufacturing building a manufacturing surface of improves the quality of the die geometry.
about 350 m² was added. This new area contains all manufac-
turing machines for turning die bodies. At present, the forged
semi-finished bodies are processed on three vertical lathes.
Additionally, the two existing and well-proven lathes were
equipped with a new control technology. This measure com-
bines the solid mechanical components of the machine with a
very modern CnC technology. As a result, the process flow in
die manufacturing was optimised and the manufacturing ac-
curacy of the dies was improved.
We also invested in a new vertical lathe. On this vertical lathe,
dies up to a diameter of 1600 mm can be received by the hy-
draulically operated power chuck and processed in parallel by
two working units. Two pick-up disk magazine tool-changers
with 16 tool pockets each ensure short tool changing times.
Besides, the machine is equipped with a combined drilling and
milling spindle for drilling holes or milling threaded bores into
the dies. A modern control system provides quick feed motions
and a precise approach of the selected positions. The working
area of the machine is equipped with a solid casing and allows
crane loading from the top or the front.
The investment in three more countersinking and reaming ma-
chines marked another milestone in the modernisation of die
manufacturing facilities. The new machining centres can recei-
ve dies with diameters of up to 1600 mm. The die is processed
by two working spindles which can be used simultaneously. Ad-
ditionally, these machines allow other processing methods such
as drilling and thread cutting. An automatic tool changing sys-
tem with a total of 32 tool pockets is available for each working
spindle. The machines are completely enclosed and equipped
with an exemplary suction unit. Thus they provide maximum
ease of operation and operational safety for the user.
With the investment in the building and in machinery (invest-
ment volume approx. € 2.5 million), the die manufacturing area
has been remodelled to meet future demands. These measures
NEW BENDING MACHINE FOR APPARATUS CONSTRUCTION
The installation of a new bending machine was a major contribution to the modernisation and extension of the sheet metal working
unit. Thanks to the new machine, the efficiency of the entire bending procedure, including programming, the set-up process, and
the actual bending process, has been improved. A safety system ensures quick and precise positioning of the pressure beam and
of the stop fingers. Due to the integrated 4-cylinder drive technology, a compression force of 320 t can be applied to the workpiece
to be bent. The CnC controlled crowning device and the integrated angular position measuring system ensure an accurate bending
result of each workpiece. The short set-up process is facilitated by a visual display and a well designed tool changing system.
AWARD FOR ExEMPLARY VOCATIONAL EDUCATION AND TRAINING
Company-based education and training play an important role in the KAHL Group. Currently we employ 40 apprentices, thus the
vocational training attendance rate in our company is about 10 % of the total number of employees. The KAHL Group offer both
commercial-technical and industrial-technical training. The professions that can be learned in industrial-technical training are
construction mechanic, cutting machine operator, and mechatronics technician; and industrial business management assistant in
commercial-technical training. We also offer a combined programme of in-company training and university studies in co-operation
with the university of Applied Sciences in Hamburg or with the »nordakademie« in Elmshorn. The degrees that can be obtained
are that of Bachelor of Science in the field of industrial engineering and Bachelor of Engineering in the field of mechanical or
electrical engineering. After a successful completion of the training programme or the studies, the students and apprentices usu-
ally remain employed in the company.
The company Amandus Kahl has been awarded the Apprenticeship Award by the IHK (Chamber of Industry and Commerce) for
exemplary performance in in-company training.
Fig. 1 and Fig. 2 new bending machine for apparatus construction Fig. 3 new die boring machine
1 2 3
/amandus kahl / nEuhaus nEoTEC / F. h . sChulE
D - 21465 Reinbek
Phone: +49 (0) 40 - 72771 - 0
Fax: +49 (0) 40 - 72771 - 100
AMANDuS KAHL GmbH & Co. KG NEuHAuS NEotEC Maschinen- und F.H. SCHuLE
Dieselstrasse 5-9 Anlagenbau GmbH Mühlenbau GmbH
D - 21465 Reinbek Dieselstrasse 5-9 Dieselstrasse 5-9
Phone: +49 (0) 40 - 72771 - 0 D - 21465 Reinbek D - 21465 Reinbek
Fax: +49 (0) 40 - 72771 - 100 Phone: +49 (0) 40 - 72771 - 500 Phone: +49 (0) 40 - 72771 - 700
E-mail: email@example.com Fax: +49 (0) 40-72771 - 550 Fax: +49 (0) 40 - 72771 - 710
www.akahl.de www.neuhaus-neotec.de www.schulefood.de
Joachim Behrmann Silke makoben Bernd Kruse
Jan Behrmann Ralf Torenz Carl-Ludwig Bollweg
Bernd Ottlinger Ralf Lippert Sylvia Becker
Olaf nährig Wilhelm mittelstädt Wolfgang Brümmer
Dr. Heinrich Graf von Reichenbach Wulff Schmidt
Dr. Stephan Sternowsky melanie Forner
Dr. michael Dolud
Dr. Werner Sitzmann
Dr. manfred Heinrich
Fritz A. Kahl
Design & composition: Printing
FARGo™ GK Druck Gerth und Klaas GmbH & Co. KG
Köhnestrasse 8 Sieker Landstraße 126
D - 20539 Hamburg D - 22143 Hamburg
Phone : +49 (0) 40 - 79 75 06 78 Phone : +49 (0) 40 - 675 668 - 0
Fax : +49 (0) 40 - 79 75 06 79 Fax : +49 (0) 40 - 675 668 - 11 oder -12
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