Veltins upgrades capacity by 130,000 glass bottles per hour

The road to Grevenstein runs right through the idyllic Sauerland region in the heart of Germany, winding its way through small villages and over hilly terrain. You won’t find a single big city within an hour’s drive. However, you will spot something rather unexpected, when all of a sudden brewery buildings and fermentation and maturation tanks many stories high come into view. And then, around the next bend you’ll find yourself amid a bustling scene of truck loading and unloading. It’s hardly surprising, really. Because the quiet village of Grevenstein – home to just 1,000 inhabitants – is also the site of one of Germany’s biggest family-owned-and-operated breweries.

C. & A. Veltins has been brewing beer since 1824. The company’s slogan, “Passion is what connects us”, is aptly chosen because it has been reflected in the company’s philosophy from the very beginning. Veltins’ success is owed in large part to the dedication of its namesake family. Susanne Veltins has been the fifth generation of family leadership at the brewery for three decades now. This passion for the craft of brewing and beer is characteristic not only of the family but also of the brewery’s 700-strong team of employees. Anyone who has ever visited Grevenstein knows that each and every one of them is passionate about their work, with a smile that clearly says, “working here is fun”!
Continuity in leadership, team spirit and of course a passion for crafting high-quality products – this combination is surely one of the reasons why Veltins ranks among the top ten breweries in Germany today. What’s especially gratifying is that Veltins’ sales of traditional beer and non-alcoholic beers alike continue to rise despite a general stagnation in the German beer market.

“Changing saddles at a full gallop”

This year, 2024, is a particularly auspicious one for C. & A. Veltins – not only because it is the brewery’s 200th anniversary but also because it marks a major milestone in the brewery’s technological evolution. A project that was launched ten years ago – the expansion of the existing plant – has now finally reached completion. This massive project has involved extensive investment, the planning of which began back in 2014. “We’ve been seeing a trend toward diversification in the market for the past 25 years, and we’re continuously growing our portfolio to match it. Today, we make 16 different products and fill them into bottles, kegs and cans. In order to best accommodate this diversity and rising demand, we needed additional production capacity. But we also needed to expand our logistics processes,” explains Peter Peschmann, Technical Director at C. & A. Veltins.
 

Initially, the plan was simply to replace one returnable-glass line. It had become apparent that the line, which was Veltins’ biggest at the time with a rated capacity of 80,000 glass bottles per hour, would soon need to be retired after many years of dependable service. However, the rapidly evolving beer market and rising sales prompted Veltins to opt to “change saddles at a full gallop”, as Peter Peschmann describes it. And so, the family-owned-and-operated brewery decided to order a second line in addition to the planned replacement. Because this is a family enterprise that takes the long view.

Built right into the hillside

As is so often the case, it was easier said than done. Before the two lines could be installed, space had to be carved out for them – out of the hillside, that is. The local topography in Grevenstein is very limiting, and the existing bottling hall backed right up to the flank of a high hill. The only option for expanding the brewery’s footprint was to cut into the hillside. And that is precisely what Veltins did. In 2019, 50,000 cubic meters of rock were blasted and hauled away – and in their place, a six-story building was erected to which additional levels can be added at a later stage.

Krones was already involved in this early project phase. “Because it wasn’t enough to simply deliver the filling lines. Since they were to be installed in the third and fifth floors of the building, it was essential that the layout be planned with the utmost precision,” says Peter Peschmann. Depending on where each line would stand, the ground and framing would have to be appropriately prepared and steel plates installed or sufficiently sloped drainage channels planned into the floor. “All of that was designed – and of course executed – down to the last centimeter. The team was really excellent to work with,” he adds.

One ultra-flexible, one lightning fast

Once construction of the building was complete, the first lines were brought in, starting in early 2022. Line 6 came first. It is dimensioned for 50,000 returnable glass bottlers per hour and is able to handle the entire portfolio. In order to guarantee this level of flexibility, the line is equipped with a LinaFlex pasteurizer plus a Linapac II packer capable of putting both the stubby “steinie” and long-neck bottles as well as six-packs into returnable crates of 16, 18, 20 and 24 . This line has been up and running since 2022, operating three shifts a day, five days a week.

In August 2023, the project that had been at the top of the agenda back in 2014 finally got underway: replacing the existing 80,000-bph returnable-glass line. This one, identified as Line 5, is designed for volume, primarily filling the flagship brand Veltins Pilsener into 0.33- and 0.5-liter bottles with a relief of the Veltins name on the neck. With the exception of the pasteurizer, this line features the same machines as Line 6 – but with one small but important difference: In order for it to reach the high speed of 80,000 containers per hour, Krones integrated not one but two of every machine (except for the double-end bottle washer and the unpacker). In other words, there are two Modulfill fillers, two Ergomatic Pro labelers, two inspectors of each type, two Linapac II packers and two Modulpal Pro machines at either end for unloading and loading pallets. 

Focus on energy and media consumption and product safety

Although both Krones lines have only been in operation for a relatively short time so far, Veltins has already seen significant improvements in energy and media consumption. “I’ve been pleasantly surprised by the complex 50,000-bph line’s low energy consumption. It’s over 30 percent less than that of a comparable line that was installed in 2007,” says Peter Peschmann. “In terms of water consumption, too, the high-speed line is saving us around 30 percent over the predecessor line. You can really very clearly see the advances that have been made here.”

In terms of product safety, too, Krones was able to set new standards with the two new lines. Between the two, there are a total of three Linatronic AI empty bottle inspectors, which use deep learning, in other words artificial intelligence. “And I must say, the detection accuracy of the Linatronic units really is exceptionally high. We regularly run test bottles to challenge our inspectors – and the Linatronic stands out for having especially low false reject rates. That’s a significant gain for us in terms of process reliability,” says an enthusiastic Peter Peschmann. “When it comes to consumer safety, it is clear that high-precision inspectors like this are the way forward. They allow us to reliably detect and remove faulty bottles.” This also holds great potential for optimizing production by reducing the number of false rejects resulting from water droplets or the like. Besides the new Linatronic AI, Veltins has integrated two additional full-bottle inspectors into Line 5. According to Peter Peschmann, these units far exceeded expectations right from the start, with extremely low false reject rates even without the AI features. 

I’ve been pleasantly surprised by the complex 50,000-bph line’s low energy consumption. It’s over 30 percent less than that of a comparable line that was installed in 2007. In terms of water consumption, too, the high-speed line is saving us around 30 percent over the predecessor line. You can really very clearly see the advances that have been made here. Peter PeschmannVeltins Technical Director

Always eager to listen

The high combined output of 130,000 containers per hour, the technical features and areas of focus as well as successful installation on the third and fifth floors are a testament to the exacting standards to which C. & A. Veltins brewery held this project. “Right from the start, we defined a comprehensive set of specifications, with precise specifications for pack complexity, for the lines’ technical equipment and energy consumption and much more. Working out a suitable concept was a months-long process. And in the end, it was the team from Krones who offered the most convincing and coherent integrated concept,” says Peter Peschmann. “And when you look now and see how quickly we’ve brought the two lines into service, it is clear that we made the right choice.”

They’re all on the same page when it comes to how they approach a project and how they get things done – and they’re always willing to listen to our needs. That certainly sets Krones apart. Peter PeschmannVeltins Technical Director

The fact that the two companies already had a track record of successful collaboration was certainly an advantage. They had previously implemented projects not only in filling but also in the brewhouse and tank cellar. “I personally have always known Krones to be a dependable partner. Honest and clear communication across all levels is certainly a signature feature of Krones. From sales and project management to the service team right through to the company’s executives, they’re all on the same page when it comes to how they approach a project and how they get things done – and they’re always willing to listen to our needs. That certainly sets Krones apart,” says Peter Peschmann. 

Ready for the future

Although the schedule was ambitious, Veltins and Krones managed to complete the commissioning of the second line, too, in time for the brewery’s 200th birthday celebration. “The entire campaign showcases not only the innovative spirit of our family-run brewery. It is also a testament to our commitment to Grevenstein,” emphasizes Peter Peschmann. “We may be one of the leading breweries in Germany, but we are also very deeply rooted in this region. The Rhein/Ruhr metropolitan area – with its 18 million inhabitants – is our main market, accounting for around 65 percent of our overall sales. And for people in the Ruhr district, Sauerland is a piece of home. Which is why we made a conscious decision to invest right here.” Veltins intends to continue its strategy of the last 25 years, maintaining its traditional brand identity with Pilsner but also remaining open to innovative trends. And with its two new lines from Krones rolling out a combined 130,000 bottles per hour, Veltins has the technology it needs to achieve those goals and then some.