Mittelstandspresse
15.09.2025
Sequential overhaul of filling valves: KHS makes maintenance faster, more flexible and more reliable
Further development of the tried-and-tested service concept / Shorter downtimes, down from up to two weeks to around ten hours / Greater flexibility thanks to new testing equipment and adapter plate
Dortmund, 15.09.2025 (PresseBox) - Even less downtime, even greater performance: The KHS Group has consistently further developed the sequential overhaul of filling valves, also known as rolling maintenance. This means that customers can significantly reduce the downtime of their fillers, work more flexibly, and permanently increase the availability of their systems.
The sequential overhaul of filling valves is based on a simple but effective principle, which translates directly into measurable benefits for the customer, as Torben Brill, Service product manager at KHS GmbH explains. “Instead of shutting down the entire filling machine for a time-consuming full overhaul, at plannable intervals only as many filling valves are removed at once as there are in a replacement set – typically around 20 of them.” KHS fillers are equipped with 125 filling valves on average, depending on the container category and machine type. To overhaul all the valves in the traditional way, two employees normally need up to two weeks. But for sequential overhaul of the filling valves, a complete set of replacement valves can be changed in just two hours. After changing, customers can put the fillers straight back into operation again, although before that the valves are overhauled and tested for leaks using a mobile overhaul and test station. That reduces the error rate on startup to under 1%, and downtime from around two weeks to about 10 hours. “It significantly reduces downtime and ensures that production can start again more quickly and with quality that has been tested,” summarizes Torben Brill.
Advanced HMI and flexible test procedures
To make this process even more efficient and flexible for beverage bottlers, KHS has specifically improved the technology that is used. An advanced HMI now lets you choose between different test procedures, and a new adapter plate decouples the filling valve from the base plate. This means a single test kit can be used for different types of filling valve – a major benefit for sites with several types of filler. For customers, that means less equipment, shorter maintenance cycles, and valve quality that has been tested before installation. Torben Brill emphasizes that “KHS is continuously developing its products further, always taking specific customer requirements into account.” “We think it’s important to not only provide our customers with a technical upgrade, but also to make their day-to-day production work noticeably easier.”
Service made to measure
KHS takes the workshop directly to the customer; with a mobile overhaul and test station, all work can be carried out on site. Customers decide whether to carry out the process themselves or have KHS personnel do so. The all-inclusive, trouble-free package contains everything needed for one year – from measuring devices and an automatic testing device through spare and wear parts to sealing rings and easy-to-understand installation and operating instructions.
The service is available as part of a multi-year contract, with the test kit provided to the customer on loan free of charge. Prior to every assignment, KHS service specifically checks whether the customer's filling valves are suitable for the process, thereby ensuring optimum application.
Ansprechpartner
Alisa Altrock
+49 251 6255 6123
Zuständigkeitsbereich: external PR consultant
Über KHS GmbH:
The KHS Group is one of the world’s leading manufacturers of filling and packaging systems for the beverage and liquid food industries. Besides the parent company (KHS GmbH), the group includes various subsidiaries outside Germany, with production sites in Ahmedabad (India) and Waukesha (USA), Zinacantepec (Mexico), São Paulo (Brazil) and Kunshan (China) It also operates numerous sales and service centers worldwide. KHS manufactures modern filling and packaging systems for the high-capacity range at its headquarters in Dortmund, Germany, and at its factories in Bad Kreuznach, Kleve, Worms and Hamburg. The KHS Group is a wholly owned subsidiary of the SDAX-listed Salzgitter AG corporation. In 2024 the KHS Group and its 5,626 employees achieved a turnover of around €1.654 billion.
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“We think it’s important to not only provide our customers with a technical upgrade, but also to make their day-to-day production work noticeably easier,” says Torben Brill, Service product manager at KHS GmbH.
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A new adapter plate decouples the filling valve from the base plate.
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Further development of the sequential overhaul of filling valves means a single test kit can be used for different types of filling valve – a major benefit for production sites with several types of filler.
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