Krombacher’s proactive investment policy for the dry end

“Keep line stops to a minimum” is the watchword for the project being jointly implemented by Krombacher and Krones. After all, the last thing the brewery needs right now is lengthy downtimes, as demand for its beers, beer-based mixed drinks and soft drinks remained high throughout 2024 despite the German beer market shrinking. 

In order to prepare itself for future challenges, Krombacher decided in 2021 to upgrade part of its existing machines, since some of its lines had already been providing continuous service for over 30 years. 

Kickoff: joint planning of the factory-restructuring project 

The brewery then contacted Krones with its requirements and commissioned the factory-planning team to draw up the best possible strategy for the upcoming mammoth project of replacing machines in no less than four lines. The team soon realised that this task called for a radical rethink of all existing production sequences. To give but two examples: One empties palletiser had previously served two lines but in future each line is to get its own system. And certain process steps that used to be performed by hand are to be automated. The overarching purpose is clear: ensuring efficient production sequences. “Master planning is aimed at establishing plant and factory structures that will boost the brewery’s success now and in future. It basically involves mapping out consistent guidelines for plant development that can be adapted to suit various market requirements. Each of the project’s three parts – analysis, target formulation and evaluation – was drawn up in detail in conjunction with Krones and together, they provide a solid basis for implementing the individual construction stages,” explains Rainer Bub, head of the project management department at the Krombacher Brewery. 

When the time came for implementation, the decision-makers at Krombacher chose Krones once again. The project plan itself bears a certain resemblance to the planning for open-heart surgery! Krones will replace the dry ends of four lines with new kit over a period of two and a half years – with no more than one week downtime per subproject. “The logistics constitute a major challenge here: The new machines and conveyors must be delivered just in time in several part shipments, brought into the hall and erected straight away because storage space on site is at a premium, and we have to minimise downtimes, of course,” says Günther Baumann, the project manager responsible at Krones. “That means we have to install platforms and remove certain line parts before the new kit arrives. And let’s not forget systems like ventilation, energy and lighting, which are Krombacher’s responsibility. All these peripherals must also be available punctually on the dates specified. So a well-structured time schedule backed by close cooperation between all the parties involved is of vital importance for successful completion of such a complex project.” 

Refurbishment – the details 

Autumn/winter 2024/2025 

In late 2024, the project kicked off with three updates installed at the start of the lines. The Krombacher Brewery first took delivery of three Pressant Universal 1A bulk-glass sweep-off depalletisers which were to replace two existing systems. The crates with returnables had previously been sorted by hand, but that will in future be handled by a Varioline selective unpacker in each line. “Selective” because this machine removes foreign bottles from the crates but leaves the Krombacher bottles in place, so they can be fed into the line. Krones also supplied four new Modulpal Pro empties palletisers, which enable crates with surplus empties to be taken directly to the warehouse. 

Autumn/winter 2025/2026 

The project will be continued in autumn 2025 when two new Modulpal Pro machines will be installed. These will provide single-type palletising of the selectively unpacked foreign empties. The Krombacher Brewery will also take delivery of four Modulpal Pro palletisers for filled and packaged products that load the crates of fulls on pallets, which are then taken to either the warehouse or the dispatch zone. 

Four more Modulpal Pro machines will follow in early 2026, which will depalletise both crates from the returnables loop and presorted empties, plus another Varioline packer for selective unpacking of foreign bottles. 

Tight schedule 

The Krombacher team deliberately chose autumn and winter for replacing the machines in two stages because, in view of the high demand for their drinks, they wanted the entire refurbishment work to take place in the low season. “Our partnership with Krones is dynamic and successful. Working together over a lengthy period on planning and implementation like we’ve been doing requires proper teamwork, mutual effort and the resolve to meet and master any new challenge together,” is how Oliver Mette, head of the system development department at the Krombacher Brewery sums up the project.