hilite - hauni maschinenbau ag · industrial designers and development engineers at hauni approach...

No. 1_2014

Published for the Tobacco Industry

UniqUe SolUtionSHauni offers perfect technical solutions for filter innovations

Hauni’s Primary Service team is ready for action 365 days a year

Hybrid power stations combine solar or wind energy with other fuels

better futureDeSign for A

HiLiTE in Big DemAnD

the hyBriD Age

there’s a lot more to an

induStrial deSigner’S job than giving

machines a decorative surface.

01_Cover_hell_DW6.indd 1 02.05.14 10:44

Max Schlatterer GmbH & Co. KGAlt-Ulmer-Straße89542 HerbrechtingenGermanyPhone +49(0)7324/15-0Fax +49(0)7324/[email protected] kb

u.de

The secrets of our success ...

Quality

Service

Research and Development

Fit for Future

Made in Germany

... endless reliability!

The secrets of our success ...The secrets of our success ...our success ...

Max Schlatterer

Quality

Service


Fit for Future

04_2014_Schlatterer_Hauni_240x310_Saugband_RZ.indd 1 28.04.2014 09:47:35

Max Schlatterer GmbH & Co. KGAlt-Ulmer-Straße89542 HerbrechtingenGermanyPhone +49(0)7324/15-0Fax +49(0)7324/[email protected] kb

u.de

The secrets of our success ...

Quality

Service


Fit for Future

Made in Germany

... endless reliability!

The secrets of our success ...The secrets of our success ...our success ...

Max Schlatterer

Quality

Service


Fit for Future

04_2014_Schlatterer_Hauni_240x310_Saugband_RZ.indd 1 28.04.2014 09:47:35

H

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3E

Dit

or

ial

esigners shape our world, giving it form,

function and a future. Our job is to struc-

ture machinery and services always with

our customer in mind. So the message be-

hind “Design – Made by Hauni” is primarily

customer service – concentrating on the newest technolo-

gies and requirements, easy maintenance, user-friendliness,

safety and sustainability.

This issue of HiLiTE looks at some of the ways in which our

industrial designers and development engineers at Hauni

approach the design process. One example is Hauni’s re-

sponse to the increasing need for future-oriented filter

making machinery which has led to flexible solutions like

KDF 5 LEAD, our FLEXPORT platform and KDF 2ER’s non-

wrapped acetate modules. They all allow manufacturers to

create high-quality, innovative filters. Another project has

been the redesign of our VARIOS-V cigarette and filter rod

reservoir system. Here again, Hauni developers have man-

aged to meet all specifications in terms of flexibility, depend-

ability and easy operation. Our Sodim and Borgwaldt KC

measurement instruments have as well been successfully

remodeled to take account of these factors.

DAlso the management level of our organization is designed

for the future. I would like to take this opportunity to say how

pleased I am to present Dr Jürgen Heller as a new member

of our Executive Board with responsibility for global Sales

& Services as of 1 January 2014. Dr Heller has been active

within the Business Area Tobacco since 2002 and joined the

company management as Executive Vice President Sales in

2007. I am convinced that Dr Heller will play a decisive role

in shaping Hauni’s future and in successfully supporting our

valued customers in every requirement they might have.

I plan to devote more attention to the strategic development

of the Business Area Tobacco alongside my duties as an

Executive Board member of the Körber AG and CEO of

Hauni Maschinenbau AG. I do hope you enjoy reading this

new issue of HiLiTE, as this one has been specially designed

– just like our products and services – to reflect the values

which the name Hauni stands for.

Christopher Somm Dr Jürgen Heller

Chairman of the Member of the

Hauni Executive Board Hauni Executive Board

DesigneD for our

customers

03_Editorial_neu.indd 3 30.04.14 13:23

contents

competence + visions

6 The PlanT engineerMatthias Weber is Head of Customer Projects Primary at

Hauni.

8 Paradigm shifT is ParT of our jobThere’s a lot more to an industrial designer’s job than giving

machines and equipment a decorative exterior.

12 design – made by hauniThe cornerstones of machine designs that reflect the values

Hauni represents.

14 facTs & figuresMeasurement instruments for e-cigarettes – and other

product news.

16 hauni WorldWideHauni is opening a new branch in South Africa.

challenges + solutions

18 “We need safe and flexible machines”

Dr Frank Hartig, Vice President of Global Engineering at

Japan Tobacco International, spoke to HiLiTE.

22 The hybrid ageHybrid power stations combine fossil fuels with renewable

sources of energy.

28 unique soluTionsHauni offers perfect technical solutions for filter innovations.

33 accuraTe Packaging To The lasT gram

FILLUTION-LTF80 plugs a gap in the snus production pro-

cess for which there was previously no automated solution.HiL

iTE

HiLiTE

1_14

Head of Customer Projects Primary Matthias Weber 06

04_05_Inhalt.indd 4 30.04.14 13:27

contents

competence + visions

6 The PlanT engineerMatthias Weber is Head of Customer Projects Primary at

Hauni.

8 Paradigm shifT is ParT of our jobThere’s a lot more to an industrial designer’s job than giving

machines and equipment a decorative exterior.

12 design – made by hauniThe cornerstones of machine designs that reflect the values

Hauni represents.

14 facTs & figuresMeasurement instruments for e-cigarettes – and other

product news.

16 hauni WorldWideHauni is opening a new branch in South Africa.

challenges + solutions

18 “We need safe and flexible machines”


Japan Tobacco International, spoke to HiLiTE.

22 The hybrid ageHybrid power stations combine fossil fuels with renewable

sources of energy.

28 unique soluTionsHauni offers perfect technical solutions for filter innovations.

33 accuraTe Packaging To The lasT gram

FILLUTION-LTF80 plugs a gap in the snus production pro-

cess for which there was previously no automated solution.HiL

iTE

HiLiTE

1_14

Head of Customer Projects Primary Matthias Weber 06

04_05_Inhalt.indd 4 30.04.14 13:27

34 EvEn grEatEr FlExibilityThe new VARIOS-V offers greater product flexibility and

protection.

36 analysts’ hEavEn – part twoSodim and Borgwaldt KC offer a broad portfolio of test

stations for quality control of cigarettes and filter rods.

38 primary sErvicEs in big dEmandHauni’s Primary service team is ready for action 365 days

a year. Clients benefit from their experience, accuracy and

punctuality.

40 morE than an ordEring platFormThe Hauni Webshop has become an important tool – and

not just for purchasers.

experience + responsibility

42 Flight to thE grEEn canopyBotanist Francis Hallé is using an airship and an inflatable

plastic raft in his bid to gain access to rainforest treetops.

46 a housE For 300 dollarsSome 100 million people around the world are homeless.

Cheap houses could offer a solution to the problem.

48 whEn a hush Falls ovEr thE FactoryHauni works continuously to cut the noise emission of its

machines.

50 strangE smokE signalsMount Etna not only spewed out fountains of lava but also

blew smoke rings skywards.

3 Editorial51 prEviEw

Dr Frank Hartig, Vice President of Global Engineering at JTI 18

Technical solutions for filter innovations 28 spotlight on dEsign

The cover of HiLiTE 1/14 shows CAD studies of silvery metallic sur-faces. Surface studies are also important to Hauni engineers when designing new machines.

There’s a lot to discover in rainforest treetops 42

04_05_Inhalt.indd 5 05.05.14 11:38

MATTHIAS WEBER is Head of Customer Projects Primary at Hauni. He and his team design and plan components, islands, lines and even completely new production facilities for processing tobacco.

THe PLANT

engineer

06_07_Portraet.indd 6 05.05.14 13:16

MATTHIAS WEBER is Head of Customer Projects Primary at Hauni. He and his team design and plan components, islands, lines and even completely new production facilities for processing tobacco.

THe PLANT

engineer

06_07_Portraet.indd 6 05.05.14 13:16

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atthias Weber is a calm man. He listens

patiently and considers. “I only talk about

a subject when I really understand it,” he

says. Then he explains clearly what ex-

perience has taught him to be important,

for example the difference between a mechanical and a plant

engineer. “The focus in the Secondary is producing cigarettes

and pack them – starting with cigarettes. This is a mechanical

process. But in the Primary we deal with process technology

and chemical processes,” he says outlining the difference. He

describes himself as „with a passion for plant engineer“.

Weber graduated in processing and process technology

from the Technical University of Dresden. He has worked

in both the pharmaceutical and chemical industries, most

recently spending 14 years in the Siemens Group. “Among

all these automation specialists, I felt a little exotic,” he re-

members. From 2002 to 2004, he completed a MBA while

continuing his career with the company. Weber joined Hauni

in June 2012. Since 2013, he has been leading a team of 15

engineers as Head of Customer Projects Primary.

“I think of us as a kind of workshop for developing and pro-

ducing offers,” he describes his work. “We work together

with Sales designing plants for the Primary.” The team com-

bines technical components, links them into logistics solu-

tions, designs production layouts, implements customer

wishes and, finally, calculates the prices for the design.

“We plan and design plant components, islands, lines and new

factories – the latter are built on green field sites.” ‘Islands’,

as the 43-year-old explains, are individual sections of a plant

within a production line. Designing a ‘line’ to be used for

processing lamina and/or cut stem or special techniques

for processing Burley tobacco is a more complex task. For

Weber’s team, the opportunity to design and plan the pro-

duction plants for a new factory is like winning the jackpot.

“Worldwide, no more than 5 to 10 projects of this kind are

put out to tender each year,” he explains. “But we only hit the

jackpot if our design and planning are successful in winning

the order from the customer.” This is the measure by which

the success of his team and the Sales team is judged.

Weber’s team submits offers for around 1,000 projects per

year, including revisions to existing offers. On average, a

project lasts for around two weeks, during which the work-

ing days tend to be somewhat longer. Motivating colleagues

and listening to them carefully are key aspects of the job.

“I don’t always know better,” he says. “I am surrounded by

clever people with a great deal of knowledge and experi-

ence.” This is why he talks with them and takes account of

their needs. Before making any decision, he weighs up the

factors at play. “I place a strong emphasis on behaving in a

way that people can understand, on transparency and clar-

ity of expression,” he says describing his style of leadership.

He applies the same principles to his 8 and 11-year-old sons.

He sees them at the weekends and on holiday. His wife lives

with their children close to Frankfurt am Main. “I work long

days and come home late. I spend nearly 50% of my time

travelling on business. My family wouldn’t hear much from

me during the week,” he is explaining the reason for dividing

his life between Frankfurt and Hamburg. And how does he

cope during the week in Hamburg? “I do the Weber triath-

lon,” he says. “One hour of running, one hour of swimming

and eight hours of sleep.” Sometimes, though, he pulls on

his leather jacket, old jeans and a T-shirt and lets off steam at

a live concert - preferably punk rock.

M

One hour of swimming is part of what Matthias Weber calls the “Weber triathlon”. The rest is: one hour of running and eight hours of sleep.

...

06_07_Portraet.indd 7 05.05.14 13:16

e’re really going to have to pit our wits at this one”, says the professor as

he presents the project. That aptly sums up one of the fundamentals for an

industrial design student: it all boils down to learning how to think – compre-

hend complex systems, focus on processes and interaction and foresee re-

sults. The project looked quite straightforward at first. It centred on a machine

designed to synthesize and analyze radioactive substances for use in nuclear medicine. A group

had developed the technology. Now that the device was ready to go into production, the group had

approached the Muthesius School of Art in Kiel, asking the young designers to add final touches.

What they wanted here was a rounded shape to house the apparatus which would one day be set

up in a laboratory. But then we started to consider the context”, recalls Detlef Rhein, whose mission

as professor is to convey to students how dramatically the demands on design professionals have

e’re really going to have to pit our wits at this one,” says the professor as


industrial design student: it all boils down to learning how to think – com-

prehend complex systems, focus on processes and interaction and fore-

see results. The project looked quite straightforward at first. It centred on a

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there’s a lot more to an industrial designer’s job than giving machines and equipment a decorative exterior.

Designers also analyze processes, add value and character to brands and control the complexities of man-machine

interaction. Sometimes they even fight for a better future.

the paraDigmshift is part of our job

WAll the objects on these pages

have won international awards

for industrial design.

What you see below is a

dentist’s chair called

“ORTHORA 200” produced by

the Swiss companay MIKRONA.

machine designed to synthesize and analyze radioactive substances for use in nuclear medicine. A

group had developed the technology. Now that the device was ready to go into production, the group

had approached the Muthesius School of Art in Kiel, asking the young designers to add final touches.


up in a laboratory. But then we started to consider the context,” recalls Detlef Rhein, whose mission


08_11-Machinery_Design.indd 8 30.04.14 13:40

e’re really going to have to pit our wits at this one”, says the professor as


industrial design student: it all boils down to learning how to think – compre-

hend complex systems, focus on processes and interaction and foresee re-

sults. The project looked quite straightforward at first. It centred on a machine

designed to synthesize and analyze radioactive substances for use in nuclear medicine. A group

had developed the technology. Now that the device was ready to go into production, the group had

approached the Muthesius School of Art in Kiel, asking the young designers to add final touches.


up in a laboratory. But then we started to consider the context”, recalls Detlef Rhein, whose mission


e’re really going to have to pit our wits at this one,” says the professor as


industrial design student: it all boils down to learning how to think – com-

prehend complex systems, focus on processes and interaction and fore-

see results. The project looked quite straightforward at first. It centred on a

8 H

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co

mpe

ten

ce

+ v

isio

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there’s a lot more to an industrial designer’s job than giving machines and equipment a decorative exterior.

Designers also analyze processes, add value and character to brands and control the complexities of man-machine

interaction. Sometimes they even fight for a better future.

the paraDigmshift is part of our job

WAll the objects on these pages

have won international awards

for industrial design.

What you see below is a

dentist’s chair called

“ORTHORA 200” produced by

the Swiss companay MIKRONA.

machine designed to synthesize and analyze radioactive substances for use in nuclear medicine. A

group had developed the technology. Now that the device was ready to go into production, the group

had approached the Muthesius School of Art in Kiel, asking the young designers to add final touches.


up in a laboratory. But then we started to consider the context,” recalls Detlef Rhein, whose mission



changed. We’ve come a long way since the days of little mouldings and racing strips, says Rhein,

referring to a bygone era of product design. Nowadays it’s all about concepts, contexts and compe-

tence. “That paradigm shift is an integral part of our profession”, he says. “We encounter it every day.”

esigners help improve people’ s lives

That meant looking at who the machine was designed to help: patients with sus-

pected cancer. So the students planned their approach taking account of the pa-

tients’ situation, their state of mind and the processes they underwent at the clin-

ic. These included complex diagnosis procedures.Treatments were interspersed

with repeated long treks from one department to another and periods of anxious waiting. “Patients

who find themselves in such a situation are fundamentally distressed”, Rhein concludes, “and

designers have a role to play in helping them feel better.” The students took a practical approach,

walking the routes themselves and analyzing the sequences involved in diagnosis and treatment.

Finally, they suggested restructuring the entire procedure, networking and dovetailing all the steps

to produce a clearly structured process with everything in one place. The idea inspired confidence

in the patients. Everything now revolved around them. They knew what was going on and what

was coming next. They felt less frightened. In the end, the machine which had been ordered for a

medical laboratory ur into a come.

industrial designers help to shape changes in technology, business an d society

With a history of success stories like this, industrial design is by no means confined to devising the

kind of packaging that will make a customer’s eyes light up. Sustainability, for instance, is now a well-

established principle which governs the way people use technology – not only those who invest in it

changed. “We’ve come a long way since the days of little mouldings and racing strips,” says Rhein,

referring to a bygone era of product design. Nowadays it’s all about concepts, contexts and compe-

tence. “That paradigm shift is an integral part of our profession,” he says. “We encounter it every day.”

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introducing the

lightweight robot

“LBR iiwa”. The

German robotics

company KUKA

presented this intel-

ligent industrial

work assistant at the

Hanover Fair 2013.

esigners help improve people’s lives

That meant looking at who the machine was designed to help: patients with sus-

pected cancer. So the students planned their approach taking account of the pa-

tients’ situation, their state of mind and the processes they underwent at the clinic.

These included complex diagnosis procedures.Treatments were interspersed with

repeated long treks from one department to another and periods of anxious waiting. “Patients who

find themselves in such a situation are fundamentally distressed,” Rhein concludes, “and designers

have a role to play in helping them feel better.” The students took a practical approach, walking the

routes themselves and analyzing the sequences involved in diagnosis and treatment. Finally, they

suggested restructuring the entire procedure, networking and dovetailing all the steps to produce a

clearly structured process with everything in one place. The idea inspired confidence in the patients.

Everything now revolved around them. They knew what was going on and what was coming next.

They felt less frightened. In the end, the machine which had been ordered for a medical laboratory

turned into a competency centre.

industrial designers help to shape changes in technology, business and society

With a history of success stories like this, industrial design is by no means confined to devising the

kind of packaging that will make a customer’s eyes light up. Sustainability, for instance, is now a

well-established principle which governs the way people use technology – not only those who invest


and are therefore concerned about efficiency, stability and ease of maintenance, but also those

who have come to realize the importance of responsibility in their daily lives. The factors that count

are quality, usability and above all integration within meaningful holistic concepts. “Design can be

equated with user-friendliness, safety at work, longevity, innovative materials and conservation of

resources”, says Baden-Württemberg’s Ministry of Trade and Commerce in the guide it has issued

for companies. Stefan Eckstein, President of the Association of German Industrial Designers, for-

mulates a claim and an obligation on behalf of his colleagues: “Industrial designers help to shape

the way in which technology, business and society c ha”

Change technology? That ought to be possible with the help of ideas and innovative drive. But busi-

ness? It seems a bold claim – yet its truth has been demonstrated by successful brands and great

ideas: the VW beetle, the iPhone, the Heidelberg printing machine and the Coca Cola bottle.

ndustrial design now focusng on proc e sses and functions

But how much “society” is in a lawnmower, a shunting engine, the interior of an ICE rail-

way carriage or a low-temperature industrial-size hot water boiler? All these items and

services have recently received design awards. Do they really make a statement that

goes beyond the object? “Well, wouldn’t you agree that a lawnmower says something

about the person who uses it – like aims, or personal standards?” Detlef Rhein returns the ques-

tion. And soon the design expert has progressed from mowers to the subject of terrace-house liv-

ing and alternatives for the future, and from there to country-to-city migration, new urban concepts

and changing views on possession and ownership. Just as quickly he turns his attention to car

sharing and electromobility, ideas whose appeal as alternatives to the petrol guzzler on the street

in front of the house is on the increase.ne of his

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in it and are therefore concerned about efficiency, stability and ease of maintenance, but also those




resources,” says Baden-Württemberg’s Ministry of Trade and Commerce in the guide it has issued

for companies. Stefan Eckstein, President of the Association of German Industrial Designers, formu-

lates a claim and an obligation on behalf of his colleagues: “Industrial designers help to shape the

way in which technology, business and society change.”




i

An amphibious light sport aircraft

named “A5”. The two-person plane

was developed and designed by

US-based consumer sportplane

manufacturer ICON AIRCRAFT.

co

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ndustrial design now focusing on processes and functions






tion. And soon the design expert has progressed from mowers to the subject of terrace-house

living and alternatives for the future, and from there to country-to-city migration, new urban con-

cepts and changing views on possession and ownership. Just as quickly he turns his attention

to car sharing and electromobility, ideas whose appeal as alternatives to the petrol guzzler on the

street in front of the house is on the increase.


and are therefore concerned about efficiency, stability and ease of maintenance, but also those




resources”, says Baden-Württemberg’s Ministry of Trade and Commerce in the guide it has issued

for companies. Stefan Eckstein, President of the Association of German Industrial Designers, for-

mulates a claim and an obligation on behalf of his colleagues: “Industrial designers help to shape

the way in which technology, business and society c ha”




ndustrial design now focusng on proc e sses and functions






tion. And soon the design expert has progressed from mowers to the subject of terrace-house liv-

ing and alternatives for the future, and from there to country-to-city migration, new urban concepts

and changing views on possession and ownership. Just as quickly he turns his attention to car

sharing and electromobility, ideas whose appeal as alternatives to the petrol guzzler on the street

in front of the house is on the increase.ne of his

10

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4

in it and are therefore concerned about efficiency, stability and ease of maintenance, but also those




resources,” says Baden-Württemberg’s Ministry of Trade and Commerce in the guide it has issued

for companies. Stefan Eckstein, President of the Association of German Industrial Designers, formu-

lates a claim and an obligation on behalf of his colleagues: “Industrial designers help to shape the

way in which technology, business and society change.”




i

An amphibious light sport aircraft

named “A5”. The two-person plane

was developed and designed by

US-based consumer sportplane

manufacturer ICON AIRCRAFT.

co

mpe

ten

ce

+ v

isio

ns

ndustrial design now focusing on processes and functions






tion. And soon the design expert has progressed from mowers to the subject of terrace-house

living and alternatives for the future, and from there to country-to-city migration, new urban con-

cepts and changing views on possession and ownership. Just as quickly he turns his attention

to car sharing and electromobility, ideas whose appeal as alternatives to the petrol guzzler on the

street in front of the house is on the increase.


has just lic transport. It involves buses which are magnetically guided using

inductive current, eliminating the need for a timetable and bus stops. Pas-

sengers get on and off wherever it is most convenient. Design has moved

inwards from the surface towards functions and processes. Now it is bring-

ing those functions and processes up to the surface to create interfaces. In-

terface design is pure psychology. It requires an awareness of the perceptive faculties and

requirement structures of the person controlling a machine. Anyone entering a car manu-

facturer’s assembly shop may see nothing but robots. They too are the work of designers

who have studied the laws of physics and logistics processes and have harnessed that

knowledge in the engineering world. The human staff have their own control room where

screens enable them to monitor and adjust processes. A smartphone’s touch screen or the

control modules on the bridge of a vessel are examples of the interfaces which designers

use to connect with tec.

aesthetics always plays the leading rofsffe

What is taste? Taste cannot express more than a vague feeling of wellbeing. The design professor

from Kiel does admit he feels emotionally moved by the clear lines of a Fiskars axe or the powerful

feel of a Hilti drill. And then Detlef Rhein makes a statement that seems to contradict everything

he has been saying about context and systems: “Aesthetics always plays the leading role.” As his

most convincing example he cites VW’s manufacturing system which assembles the Touareg, the

Porsche Cayenne and the Audi Q7 all on the same platform. There is far more similarity between

these off-roaders than the difference in price would seem to indicate. The value of the product is

not defined by materials but in social terms. That too, holds Rhein, is an aspect of the aesthe.

ne of his students, Simon Koch, has just received an award for devising a new idea

for local public transport. It involves buses which are magnetically guided using

inductive current, eliminating the need for a timetable and bus stops. Passengers

get on and off wherever it is most convenient. Design has moved inwards from the

surface towards functions and processes. Now it is bringing those functions and

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Forklift truck “R70 Hybrid”. The first counter balance truck produced in series worldwide

is using the principle of energy recuperation in combination with an electric power transmission.

processes up to the surface to create interfaces. Interface design is pure psychology. It requires an

awareness of the perceptive faculties and requirement structures of the person controlling a ma-

chine. Anyone entering a car manufacturer’s assembly shop may see nothing but robots. They too

are the work of designers who have studied the laws of physics and logistics processes and have

harnessed that knowledge in the engineering world. The human staff have their own control room

where screens enable them to monitor and adjust processes. A smartphone’s touch screen or the

control modules on the bridge of a vessel are examples of the interfaces which designers use to

connect with technology.

aesthetics always play the leading role

What is taste? Taste cannot express more than a vague feeling of wellbeing. The design professor

from Kiel does admit he feels emotionally moved by the clear lines of a Fiskars axe or the powerful

feel of a Hilti drill. And then Detlef Rhein makes a statement that seems to contradict everything he

has been saying about context and systems: “Aesthetics always play the leading role.” As his most

convincing example he cites VW’s manufacturing system which assembles the Touareg, the Porsche

Cayenne and the Audi Q7 all on the same platform. There is far more similarity between these off-

roaders than the difference in price would seem to indicate. The value of the product is not defined

by materials but in social terms. That too, holds Rhein, is an aspect of the aesthetics of design.


he design of our machines must benefit the customer,” insists Matthias Overath, Product

Manager Cigarette. That brief statement sums up a complex process, a major focus of

attention at Hauni. Designing new machines is a task involving intense and well-coordina-

ted cooperation within a team of engineers, machine designers, industrial designers and

marketing experts. “Features requested by customers and market trends go straight into

the designing process,” adds Overath.

Emerging needs, new technologies

A new machine like KDF 5 naturally has to incorporate state-of-the-art technology and meet manufactu-

rers' emerging needs whilst fulfilling Hauni quality standards. The first steps in the design process are to

analyze any weak points and to continue evolving established technologies. To take filter making as an

example: the LEAD option available for KDF 5 and FLEXPORT are a response to manufacturers' incre-

asing need for flexibility. Filter length and diameter can now be changed rapidly. New technologies like

direct drives and intelligently automated calibration have been incorporated to streamline size changing.

The modular FLEXPORT sy

-changing to maximize filter maker convertibility. “Another aspect of our job is to develop interfaces we

will be able to use on future versions of the machine, to connect feed and discharge units or measuring

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he design of our machines must benefit the customer,” insists Matthias Overath, Prod-

uct Manager Cigarette. That brief statement sums up a complex process, a major focus

of attention at Hauni. Designing new machines is a task involving intense and well-

coordinated cooperation within a team of engineers, machine designers, industrial desi-

gners and marketing experts. “Features requested by customers and market trends go

straight into the designing process,” adds Overath.


A new machine like KDF 5 naturally has to incorporate state-of-the-art technology and meet man-

ufacturers’ emerging needs whilst fulfilling Hauni quality standards. The first steps in the design

process are to analyze any weak points and to continue evolving established technologies. To take

filter making as an example: the LEAD option available for KDF 5 and FLEXPORT are a response to

manufacturers’ increasing need for flexibility. Filter length and diameter can now be changed rapidly.

New technologies like direct drives and intelligently automated calibration have been incorporated to

streamline size changing.

The modular FLEXPORT system answers the demand for extreme flexibility whilst offering fast func-

tion-changing to maximize filter maker convertibility. “Another aspect of our job is to develop inter-

TNew technologies to meet emerging needs, easy maintenance, user-friendliness and sustainability: thE CornErstonEs of machine designs that reflect the values Hauni represents.

DesigNMaDe by

hauni

12_13_Hauni_Design.indd 12 30.04.14 13:41

he design of our machines must benefit the customer,” insists Matthias Overath, Product

Manager Cigarette. That brief statement sums up a complex process, a major focus of

attention at Hauni. Designing new machines is a task involving intense and well-coordina-

ted cooperation within a team of engineers, machine designers, industrial designers and

marketing experts. “Features requested by customers and market trends go straight into

the designing process,” adds Overath.


A new machine like KDF 5 naturally has to incorporate state-of-the-art technology and meet manufactu-

rers' emerging needs whilst fulfilling Hauni quality standards. The first steps in the design process are to

analyze any weak points and to continue evolving established technologies. To take filter making as an

example: the LEAD option available for KDF 5 and FLEXPORT are a response to manufacturers' incre-

asing need for flexibility. Filter length and diameter can now be changed rapidly. New technologies like

direct drives and intelligently automated calibration have been incorporated to streamline size changing.

The modular FLEXPORT sy

-changing to maximize filter maker convertibility. “Another aspect of our job is to develop interfaces we

will be able to use on future versions of the machine, to connect feed and discharge units or measuring

12

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he design of our machines must benefit the customer,” insists Matthias Overath, Prod-

uct Manager Cigarette. That brief statement sums up a complex process, a major focus

of attention at Hauni. Designing new machines is a task involving intense and well-

coordinated cooperation within a team of engineers, machine designers, industrial desi-

gners and marketing experts. “Features requested by customers and market trends go

straight into the designing process,” adds Overath.


A new machine like KDF 5 naturally has to incorporate state-of-the-art technology and meet man-

ufacturers’ emerging needs whilst fulfilling Hauni quality standards. The first steps in the design

process are to analyze any weak points and to continue evolving established technologies. To take

filter making as an example: the LEAD option available for KDF 5 and FLEXPORT are a response to

manufacturers’ increasing need for flexibility. Filter length and diameter can now be changed rapidly.

New technologies like direct drives and intelligently automated calibration have been incorporated to

streamline size changing.

The modular FLEXPORT system answers the demand for extreme flexibility whilst offering fast func-

tion-changing to maximize filter maker convertibility. “Another aspect of our job is to develop inter-

TNew technologies to meet emerging needs, easy maintenance, user-friendliness and sustainability: thE CornErstonEs of machine designs that reflect the values Hauni represents.

DesigNMaDe by

hauni


instruments,” explains the product manager. uments,” explains the product manager.

uments,” explains the product manager.

asy to maintain, user-friendly, safe and sustainable

A machine's appeal to the customer increases if it is structured for convenient access,

simple maintenance and quick cleaning. These features help to get a unit up and running

rapidly. Operators appreciate a machine which has been designed for straightforward,

intuitive operation with the convenience of a touch panel like VISU+ to provide guidance

and support with control processes. “Operators should also be able to see what's going on inside the

machine and work on it without having to bend their backs unnecessarily. They need to be able to inter-

vene promptly if required. And low noise is important too,” says Overath. Catering for those needs means

putting light inside the machine, fitting protective doors that are easy to open as well as safety glass

windows that not only allow you to see inside but also help to reduce noise emissions, as on KDF 5, to a

level below 78 dB(A). “Technical features like the machine's water-based cooling system help to reduce

power consumption at a customer's facility, and multiple-use parts save expense in the area of spares

management,” says Overath, describing ways in which designers' decisions can lead to added value for

customers.uments,” explains

Quality you can see

The look of a machine is an important factor too, of course. The silvery sheen of this filter maker's surfaces,

the unobstructed view into its well-lit interior, its clean lines, smooth curves and compact appearance all

combine to give a visual impact reflecting the values which Hauni stands for. On the front, the unit's name

and the Hauni logo lend a finishing touch to this sleek design.

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faces we will be able to use on future versions of the machine, to connect feed and discharge units

or measuring instruments,” explains the product manager.

asy to maintain, user-friendly, safe and sustainable

A machine’s appeal to the customer increases if it is structured for convenient access,

simple maintenance and quick cleaning. These features help to get a unit up and run-

ning rapidly. Operators appreciate a machine which has been designed for straightfor-

ward, intuitive operation with the convenience of a touch panel like VISU+ to provide

guidance and support with control processes. “Operators should also be able to see what’s going on

inside the machine and work on it without having to bend their backs unnecessarily. They need to be

able to intervene promptly if required. And low noise is important too,” says Overath. Catering for those

needs means putting light inside the machine, fitting protective doors that are easy to open as well as

safety glass windows that not only allow you to see inside but also help to reduce noise emissions, as

on KDF 5, to a level below 78 dB(A). “Technical features like the machine’s water-based cooling system

help to reduce power consumption at a customer’s facility, and multiple-use parts save expense in the

area of spares management,” says Overath, describing ways in which designers’ decisions can lead to

added value for customers.

Quality you can see

The look of a machine is an important factor too, of course. The silvery sheen of this filter maker’s

surfaces, the unobstructed view into its well-lit interior, its clean lines, smooth curves and compact ap-

pearance all combine to give a visual impact reflecting the values which Hauni stands for. On the front,

the unit’s name and the Hauni logo lend a finishing touch to this sleek design.

e

The design of a filtermaker through the ages: The changing appearance of Hauni filter makers reached

its current peak with the KDF 5.

1967 1992

2014


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he measurement technology specialists

Sodim and Borgwaldt KC are ideally posi-

tioned to meet the challenges facing man-

ufacturers and suppliers in the e-cigarette

market. “Designs vary widely so measure-

ment instruments must be tailored individually,” says Thomas

Schmidt, Marketing and Business Development Manager at

Borgwaldt KC. As well as aerosol generators such as the

LX1E, which allows measuring the composition and concen-

tration of constituents of the aerosol, Borgwaldt KC supplies

instruments that determine physical and technical values. In

addition, customers can send their cigarettes to Borgwaldt’s

analytical service laboratory for analysis. The results are re-

turned electronically in four to five days.

TThe EU Tobacco Products Directive introduces European regulations for e-cigarettes. MeasureMent instruMents will thus become essential.

FACTS & figures

experts for e-cigarettes

Sodim offers a range of measurement instruments that are

compatible with e-cigarettes, such as CIGARLAB or the

smoking puff analyzer (SPA). “We developed the new SPA

adapters to take account of various shapes and diameters

of e-cigarette mouthpieces. This enables more flexibility

for our customers as they can use their device either with

conventional cigarettes or with different types of electronic

cigarettes by just connecting the suitable adapter,” says

Dr Marlène Testud, Head of Scientific and Regulatory Affairs.

Concerning the recorded parameters, the CIGARLAB meas-

ures the pressure drop of e-cigarettes, the SPA measures

puff duration, puff volume, interpuff interval of aerosol inhaled

and also pressure drop – parameters, which are also tested

for conventional cigarettes.

14_15_Facts_Figures.indd 14 30.04.14 13:43

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he measurement technology specialists

Sodim and Borgwaldt KC are ideally posi-

tioned to meet the challenges facing man-

ufacturers and suppliers in the e-cigarette

market. “Designs vary widely so measure-

ment instruments must be tailored individually,” says Thomas

Schmidt, Marketing and Business Development Manager at

Borgwaldt KC. As well as aerosol generators such as the

LX1E, which allows measuring the composition and concen-

tration of constituents of the aerosol, Borgwaldt KC supplies

instruments that determine physical and technical values. In

addition, customers can send their cigarettes to Borgwaldt’s

analytical service laboratory for analysis. The results are re-

turned electronically in four to five days.

TThe EU Tobacco Products Directive introduces European regulations for e-cigarettes. MeasureMent instruMents will thus become essential.

FACTS & figures

experts for e-cigarettes

Sodim offers a range of measurement instruments that are

compatible with e-cigarettes, such as CIGARLAB or the

smoking puff analyzer (SPA). “We developed the new SPA

adapters to take account of various shapes and diameters

of e-cigarette mouthpieces. This enables more flexibility

for our customers as they can use their device either with

conventional cigarettes or with different types of electronic

cigarettes by just connecting the suitable adapter,” says

Dr Marlène Testud, Head of Scientific and Regulatory Affairs.

Concerning the recorded parameters, the CIGARLAB meas-

ures the pressure drop of e-cigarettes, the SPA measures

puff duration, puff volume, interpuff interval of aerosol inhaled

and also pressure drop – parameters, which are also tested

for conventional cigarettes.


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Glued tipping with GaMsThe Glue Application Monitoring Sensor (GAMS) is a solution

designed to check the glue applied to each individual tipping

patch. This assures the quality of the filter attachment and

prevents filter-fall-off-related customer complaints. To elimi-

nate any badly glued or detached filters, the sensor monitors

the amount of glue directly on the tipping. The signals from

the sensor are analyzed and cigarettes with imperfectly glued

tipping are ejected on the MAX at full speed. This non-contact

optical sensor, TIP C MA 365, can be adjusted to suit differ-

ent tipping papers and to send the eject signal on reaching a

predefined limit. GAMS is available for all PROTOS makers.

tPr: individual cigarettesTipping Paper Registration (TPR): An option for individualizing

cigarette tipping paper. The solution developed for PROTOS 1C,

PROTOS 90E and PROTOS-M-generation machines defines the

cut of the tipping paper with complete precision. Once the ma-

chine is fitted with the sensors and servomotors for transporting

the tipping paper, it has the capability to control the process so ac-

curately that each paper is cut to a defined design. Tipping paper

pre-printed with images, logos or lettering can be cut in a way that:

• each individual cigarette shows a complete image

• the logo is always positioned opposite the overlap

• and your brand name is not cut.

tiPs for your aF-KDFConvert Siemens M7 PLC to the latest Siemens S7 PLC

control system. The old operator panel will be replaced

with a touch panel and an updated VISU-PC. Your ben-

efit: long-term availability of spare parts as components

for the M7 PLC are no longer supported. TIP F KD 387 is

retrofittable to AF-KDF 2E, AF-KDF 2EU, AF-KDF 2ER. To

address availability at full scope, Hauni recommends the

replacement of the MICROMASTER frequency convert-

ers with the latest Siemens frequency converters.

TIP F AF 218 includes the converters in the fan, glue

pump motors, double accelerator motors of the KDF and

in the fan, triacetin pump and brush roller drive of the AF.


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rowing economies

The populations and economies of Africa

are growing. In order to support our cus-

tomers in their rising demand, Hauni is in-

tensifying its presence and opening a new

branch in Cape Town, South Africa.

The economies are currently enjoying a boom and many

nations are growing at an impressive rate. According to

recent forecasts, the continent will be home to more than

1.6 billion people, or one fifth of the global population, by

as soon as 2030. It is estimated that by then more than

half of Africans will have joined the middle classes, live in

HAUNI

G

Hauni Far East LtdWanchai - Hong Kong

Hauni Far East LtdBeijing

Hauni Malaysia Sdn. Bhd. Shah Alam / Selangor

Hauni Far East Ltd Kunming

Hauni do Brasil Ltda. São Paulo

Decouflé s.à.r.l. São Paulo

Decouflé Americas Coral Gables / Miami

Borgwaldt KC, Inc.Richmond

Hauni Richmond, Inc.Richmond

Hauni AfricaCape Town

Hauni Maschinenbau AG Hamburg

Borgwaldt Flavor GmbH Hamburg

Decouflé s.à.r.l. Chilly-Mazarin, Paris

Sodim SAS Orléans

Hauni Hungaria GmbHPècs

Hauni Teknik Hizmetler Ve Ticaret Limited Sirketi Konak / Izmir

worldwideWe think globally, we act locally. Our staff operate where customers are located, right there In the marketplace. This policy allows us to respond promptly to requirements. Now Hauni is opening a new branch in CapeTown, South Africa.

Hauni Singapore Pte. LtdSingapore

16_17_worldwide.indd 16 30.04.14 13:43

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rowing economies

The populations and economies of Africa

are growing. In order to support our cus-

tomers in their rising demand, Hauni is in-

tensifying its presence and opening a new

branch in Cape Town, South Africa.

The economies are currently enjoying a boom and many

nations are growing at an impressive rate. According to

recent forecasts, the continent will be home to more than

1.6 billion people, or one fifth of the global population, by

as soon as 2030. It is estimated that by then more than

half of Africans will have joined the middle classes, live in

HAUNI

G





Hauni do Brasil Ltda. São Paulo

Decouflé s.à.r.l. São Paulo

Decouflé Americas Coral Gables / Miami

Borgwaldt KC, Inc.Richmond

Hauni Richmond, Inc.Richmond

Hauni AfricaCape Town

Hauni Maschinenbau AG Hamburg

Borgwaldt Flavor GmbH Hamburg

Decouflé s.à.r.l. Chilly-Mazarin, Paris

Sodim SAS Orléans

Hauni Hungaria GmbHPècs

Hauni Teknik Hizmetler Ve Ticaret Limited Sirketi Konak / Izmir

worldwideWe think globally, we act locally. Our staff operate where customers are located, right there In the marketplace. This policy allows us to respond promptly to requirements. Now Hauni is opening a new branch in CapeTown, South Africa.


16_17_worldwide.indd 16 30.04.14 13:43

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urban environments and wield considerable

purchasing power.

Hauni’s new branch

This trend is a game changer that re-

quires companies to take action today and

Hauni is taking steps that confirm its long-

term approach to business. In the South

African city of Cape Town, Hauni opened a

new branch that extends its closely-linked global

network of company locations still further.

Until now, Reitech, South Africa, also based in Cape Town,

has provided support services for Hauni’s customers

in sub-Saharan Africa. The partnership will remain with

Hauni’s team finding its home in the Reitech premises.

A strong team for the African continent

The new Hauni team is composed of specialists who are

well-acquainted with the conditions and challenges in the

region. They will operate from the premises of Reitech.

The Brazilian Kenji Guenta as General Manager for Sales &

Services will lead Hauni’s new Africa team. The production

engineer with Japanese roots and a Brazilian background

has worked for Hauni for many years as a Sales Manager.

He already provides support to North African customers

from Hauni’s home in Hamburg-Bergedorf and knows the

region well.

Together with his new young and highly qualified team in

Cape Town, he will offer customers the full range of Hauni

machines and services.


Hauni Trading (Shanghai) Co. LtdShanghai


Hauni Japan Co. LtdTokyo



OOO Hauni St PetersburgSt Petersburg

Decouflé Moscow Moscow

OOO Hauni St Petersburg Subsidiary Moscow


Hauni africa14 capricorn Boulevard northcapricorn Park, Muizenberg, 7945 cape Town, South africaPhone: + 27 (21) 709 8149E-Mail: [email protected]

...

16_17_worldwide.indd 17 30.04.14 13:43

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ou’ve been Global Engineer-

ing’s Vice President at JTI

since 2009. What are the key

challenges for that position?

Primarily it’s about new products that

JTI is planning to launch. What kind of manufacturing

processes are we going to need? How can we make

the products on our machines without overinvesting?

Then we select the best processes, draw up invest-

ment plans and schedules and finally implement the

entire project in our factories around the world. My

job also involves assessing the necessary invest-

ments in our factories, estimating investment in new

locations for evaluating acquisitions and optimizing

our manufacturing footprint.

What do you mean by “manufacturing foot-

print”?

It’s a matter of keeping a check on how many facto-

ries we need and could we benefit from synergies.

The objective is to optimize manufacturing costs.

How many factories are we talking about?

At the moment there are 25 JTI factories in 23 coun-

tries. In the past few years JT Group has acquired

locations in Sudan, Egypt and Belgium. This effort

increased the number of factories, and our products

have become more varied.

Is there a work allocation scheme for the

factories?

Each factory has its own specific focus. Some con-

centrate on products like roll-your-own or make-

your-own, others supply only cigarettes. Some are

export-oriented while others focus mainly on do-

mestic markets. Global Engineering supports all the

Global Supply Chain factories in JTI.

You’re based in Trier at the moment – isn’t

this the place where the group likes to test

new machinery?

Yes, Trier is a large facility with experienced staff and

it’s also geographically close to the major machine

manufacturers. Trier has always been very keen to

cooperate whenever new machines needed testing.

Large-scale trials are also done at other factories in

countries like Poland and Russia.

Do you test within the manufacturing con-

text or outside it?

Sometimes we keep tests separate from the produc-

tion process. Hauni’s KDF 5 is currently undergo-

ing a series of trials within our manufacturing setup.

Y

Dr Frank HarTIG, Vice President of Global Engineering at Japan Tobacco International (JTI), spoke to HiLiTE about the organization’s ongoing efforts to achieve greater safety, higher quality and lower manufacturing costs. He also outlined what the company still needs to continue optimizing production.

“WE nEEd safE and fLExIbLE macHInEs. I don’t just mean the mechanical aspects of converting a machine.”

18_21_Kundeninterview.indd 18 30.04.14 13:48

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ou’ve been Global Engineer-

ing’s Vice President at JTI

since 2009. What are the key

challenges for that position?

Primarily it’s about new products that

JTI is planning to launch. What kind of manufacturing

processes are we going to need? How can we make

the products on our machines without overinvesting?

Then we select the best processes, draw up invest-

ment plans and schedules and finally implement the

entire project in our factories around the world. My

job also involves assessing the necessary invest-

ments in our factories, estimating investment in new

locations for evaluating acquisitions and optimizing

our manufacturing footprint.

What do you mean by “manufacturing foot-

print”?

It’s a matter of keeping a check on how many facto-

ries we need and could we benefit from synergies.

The objective is to optimize manufacturing costs.

How many factories are we talking about?

At the moment there are 25 JTI factories in 23 coun-

tries. In the past few years JT Group has acquired

locations in Sudan, Egypt and Belgium. This effort

increased the number of factories, and our products

have become more varied.

Is there a work allocation scheme for the

factories?

Each factory has its own specific focus. Some con-

centrate on products like roll-your-own or make-

your-own, others supply only cigarettes. Some are

export-oriented while others focus mainly on do-

mestic markets. Global Engineering supports all the

Global Supply Chain factories in JTI.

You’re based in Trier at the moment – isn’t

this the place where the group likes to test

new machinery?

Yes, Trier is a large facility with experienced staff and

it’s also geographically close to the major machine

manufacturers. Trier has always been very keen to

cooperate whenever new machines needed testing.

Large-scale trials are also done at other factories in

countries like Poland and Russia.

Do you test within the manufacturing con-

text or outside it?

Sometimes we keep tests separate from the produc-

tion process. Hauni’s KDF 5 is currently undergo-

ing a series of trials within our manufacturing setup.

Y

Dr Frank HarTIG, Vice President of Global Engineering at Japan Tobacco International (JTI), spoke to HiLiTE about the organization’s ongoing efforts to achieve greater safety, higher quality and lower manufacturing costs. He also outlined what the company still needs to continue optimizing production.



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Japan Tobacco International, is based in Trier, Germany.


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fter completing the initial adjustments we let

it run and we finally market the finished prod-

ucts. KDF 5 is a great line – it has a really mod-

ular design and so far tests have shown it’s

extremely robust. This is a win-win situation

that lets the machine supplier run large volumes to check for

stable running and identify any points where efficiency could

be increased. The factory gets the benefit of having the sup-

port of Hauni experts on-site. As far as introducing new prod-

ucts and product configurations is concerned, there’s also a

lot going on in places like St Petersburg.

The russian market seems to be particularly keen on

trying out innovative products. Is that the reason?

We do develop a lot of new products for Russia and ciga-

rette diameters also vary quite widely. We manufacture slim

and microslim formats on a big scale there. In fact, JTI fac-

tories everywhere work on new developments, particularly in

the field of filters.

Isn’t the cigarette a fully mature product already?

Well, at JTI we’ve already reached the high levels of cigarette

and packaging quality. It’s now really a matter of maintain-

ing that standard, and yet we still keep looking for ways to

optimize. New materials, for instance, can be quite tricky to

process and we’ve got to make sure that quality isn’t com-

promised.

What kind of new materials?

Packs are now made with coated materials using special

printing and embossing techniques. The surfaces are more

sensitive than they used to be. There are new shapes too, like

the curved Camel pack. These are much harder to fold than

standard packs. These are all new challenges which we try

to address while maintaining our traditional quality standards.

Is energy conservation an issue at JTI?

Oh yes, in fact it’s a key focus area. Our objectives are to

minimize costs as well as CO2 emission levels.

JTI managed to cut its worldwide CO2 emissions by

29% since 2003. That’s quite an achievement.

We make a tremendous effort to save energy, and we’re

proud of that. Up until now, we’ve been focusing mainly on

factory baseloads. Quite a big percentage of the power we

use goes into operating air-conditioning systems, lighting,

generating compressed air and steam. We’re now teaming

up with other cigarette manufacturers to look more closely

into how much energy the machines use.

Is that likely to affect your specs for machine manu-

facturers?

Yes indeed, we’d like to see lower power consumption ratings.

What about brand and size changing – do you still

need more flexibility?

We do need quicker conversion procedures. I don’t just

mean the mechanical aspects of converting a machine. The

entire logistics process involved in switching brands needs

to be speeded up. Another point is that the variety of ma-

terials we use often still causes problems on the machines.

They need to be more rugged and better at processing light-

er-weight materials or thinner films gently.

So that’s why you’re keen to have modular machine

designs?

Actually that’s a point we brought up five or six years ago.

Hauni’s Board Chairman Christopher Somm was right in

deciding to go for modular structures. The company has

successfully implemented that policy with its M-generation

cigarette makers and is continuing to do the same thing with

the filter makers. The logistics units seem to be going the

same way.

What else would you like your machine suppliers to

provide?

Our top priority is safety, so we’re aiming for a zero accident

rate at our factories. Then there’s the question of product

configurations – their increasing variety means we either

need more machines or more flexible ones. More machines

spell more factory floor space – to run smaller volumes we

would have to expand the factory, which is what we want to

avoid. So that leaves us with a choice between more flexible

machines or ones with a smaller footprint. Our ideal maker

would be able to start with small batches and switch later

to automatic high-speed, high-volume mode. I know that’s

a tall order and not easy to implement. If you ask me what I

want, that’s my answer.

With more and more people using the internet to

transfer data, do you see security as an issue?

We do need barriers to protect our production data and are

stepping up measures to fend off any external interference

in our manufacturing processes. Actually the entire cigarette

industry is currently in the process of devising new concepts

in that area.

any suggestions to make about spare parts?

Well, modular-design machines come first, but we’d also re-

ally like to see parts standardized much more extensively to

save us having to order different parts for each unit.

What design features do you expect on a machine?

We require machines we can clean quickly. It’s essential to

have easy access to every nook and cranny. We’re dealing

here with a natural product and need to take massive ac-

a


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fter completing the initial adjustments we let

it run and we finally market the finished prod-

ucts. KDF 5 is a great line – it has a really mod-

ular design and so far tests have shown it’s

extremely robust. This is a win-win situation

that lets the machine supplier run large volumes to check for

stable running and identify any points where efficiency could

be increased. The factory gets the benefit of having the sup-

port of Hauni experts on-site. As far as introducing new prod-

ucts and product configurations is concerned, there’s also a

lot going on in places like St Petersburg.

The russian market seems to be particularly keen on

trying out innovative products. Is that the reason?

We do develop a lot of new products for Russia and ciga-

rette diameters also vary quite widely. We manufacture slim

and microslim formats on a big scale there. In fact, JTI fac-

tories everywhere work on new developments, particularly in

the field of filters.

Isn’t the cigarette a fully mature product already?

Well, at JTI we’ve already reached the high levels of cigarette

and packaging quality. It’s now really a matter of maintain-

ing that standard, and yet we still keep looking for ways to

optimize. New materials, for instance, can be quite tricky to

process and we’ve got to make sure that quality isn’t com-

promised.

What kind of new materials?

Packs are now made with coated materials using special

printing and embossing techniques. The surfaces are more

sensitive than they used to be. There are new shapes too, like

the curved Camel pack. These are much harder to fold than

standard packs. These are all new challenges which we try

to address while maintaining our traditional quality standards.

Is energy conservation an issue at JTI?

Oh yes, in fact it’s a key focus area. Our objectives are to

minimize costs as well as CO2 emission levels.

JTI managed to cut its worldwide CO2 emissions by

29% since 2003. That’s quite an achievement.

We make a tremendous effort to save energy, and we’re

proud of that. Up until now, we’ve been focusing mainly on

factory baseloads. Quite a big percentage of the power we

use goes into operating air-conditioning systems, lighting,

generating compressed air and steam. We’re now teaming

up with other cigarette manufacturers to look more closely

into how much energy the machines use.

Is that likely to affect your specs for machine manu-

facturers?

Yes indeed, we’d like to see lower power consumption ratings.

What about brand and size changing – do you still

need more flexibility?

We do need quicker conversion procedures. I don’t just

mean the mechanical aspects of converting a machine. The

entire logistics process involved in switching brands needs

to be speeded up. Another point is that the variety of ma-

terials we use often still causes problems on the machines.

They need to be more rugged and better at processing light-

er-weight materials or thinner films gently.

So that’s why you’re keen to have modular machine

designs?

Actually that’s a point we brought up five or six years ago.

Hauni’s Board Chairman Christopher Somm was right in

deciding to go for modular structures. The company has

successfully implemented that policy with its M-generation

cigarette makers and is continuing to do the same thing with

the filter makers. The logistics units seem to be going the

same way.

What else would you like your machine suppliers to

provide?

Our top priority is safety, so we’re aiming for a zero accident

rate at our factories. Then there’s the question of product

configurations – their increasing variety means we either

need more machines or more flexible ones. More machines

spell more factory floor space – to run smaller volumes we

would have to expand the factory, which is what we want to

avoid. So that leaves us with a choice between more flexible

machines or ones with a smaller footprint. Our ideal maker

would be able to start with small batches and switch later

to automatic high-speed, high-volume mode. I know that’s

a tall order and not easy to implement. If you ask me what I

want, that’s my answer.

With more and more people using the internet to

transfer data, do you see security as an issue?

We do need barriers to protect our production data and are

stepping up measures to fend off any external interference

in our manufacturing processes. Actually the entire cigarette

industry is currently in the process of devising new concepts

in that area.

any suggestions to make about spare parts?

Well, modular-design machines come first, but we’d also re-

ally like to see parts standardized much more extensively to

save us having to order different parts for each unit.

What design features do you expect on a machine?

We require machines we can clean quickly. It’s essential to

have easy access to every nook and cranny. We’re dealing

here with a natural product and need to take massive ac-

a


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says Dr Frank Hartig standing in front of a PROTOS-M8.

Winston and CAMEL are just two of the major brands

that are manufactured worldwide in the 25 factories of

Japan Tobacco International.

tion against beetles

to stop them enter-

ing the production

process. We’d also

appreciate quieter

machines – Hauni

has already achieved a great deal in that area.

Being from Hamburg, you’re passionate about sail-

ing. You won’t get much opportunity for that in Trier.

Well, it’s not exactly easy. I do try to get a chance to sail once

a year. Last year I managed to take my wife and two children

sailing on the Ijsselmeer in Holland. I’ve booked the same

again for this year. It’s a pleasant area for boating.

What else do you like doing between sailing holi-

days?

I sometimes ride my racing bike and play squash or tennis.

One thing my wife and I really enjoy is an evening out at the

excellent Philharmonie Luxembourg – they put on such fan-

tastic concerts that we’ve now got season tickets.

The objective is to optimize manufacturing costs”

“18_21_Kundeninterview.indd 21 30.04.14 13:48

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Hybrid power stations combine fossil fuels with renewable

sources of energy. this protects the environment, increases energy efficiency and helps to guarantee future electricity supplies. Around the world, an ever-growing number of conventional power stations are being converted into hybrid power stations, especially in Asia, Africa and latin America, in order to slake these continents’ growing thirst for energy.

tHehybrid age

22_25_Hybrid.indd 22 30.04.14 13:51

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Hybrid power stations combine fossil fuels with renewable

sources of energy. this protects the environment, increases energy efficiency and helps to guarantee future electricity supplies. Around the world, an ever-growing number of conventional power stations are being converted into hybrid power stations, especially in Asia, Africa and latin America, in order to slake these continents’ growing thirst for energy.

tHehybrid age

22_25_Hybrid.indd 22 30.04.14 13:51

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he tentacles of Egypt’s capital city extend

endlessly into the surrounding desert. Cairo

is Africa’s largest city and one of a number

of aspiring mega-metropolises on the plan-

et. Poverty and prosperity live side-by-side,

high-tech industries are flanked by craft businesses that ap-

pear almost unchanged since the Middle Ages. The popula-

tion is growing rapidly and with it the thirst for energy.

Cairo is a pioneer in the area of renewable energy. The

world’s first solar thermal power station went into operation

here over 100 years ago, pumping water to irrigate Egypt’s

rice fields. Today, there is a large hybrid power station a few

kilometres to the south of Cairo: the “Integrated Solar Com-

bined Cycle Kuraymat” project went online three years ago.

The power station combines solar and gas-fired generating

capacity – hence its description as a “hybrid”. The plant gen-

t

combine wind or solar energy with other fuels – like for

example in Israel. The heliostats track the sun and reflect

it towards a solar receiver (tower), where it heats com-

pressed air that drives a gas turbine. The turbine converts

the thermal energy into electricity. During the night the

turbine runs with biogas, biodiesel or natural gas.

erates around 150 megawatts (MW) of electricity. At night it

uses a conventional gas burner, during the day large solar

collectors take over: 53,000 parabolic mirrors focus the heat

of the sun’s rays onto a thermal transfer fluid. Heat exchang-

ers in the power station block convert this energy into steam,

which drives turbines to produce electricity. The power sta-

tion supplies electricity to almost two million people. Egypt

is therefore well on the way to achieving the shift over to

sustainable sources of energy.

combining energy sources

There are good reasons for doing so. CO2 emissions must

be reduced worldwide in order to reduce the threat of cli-

mate change. One effective way of doing this is by shifting

energy generation away from fossil fuels over to renewable

sources. The Intergovernmental Panel on Climate Change

(IPCC) has found that the combustion of coal, natural gas

and oil is still the largest source of greenhouse gas emis-

sions. But 140 countries around the world have already a-

dopted energy policies that combine sustainable energy with

fossil and nuclear power. Today, nearly one fifth of electricity

worldwide is generated from renewables – in 20 years’ time

this figure is forecast to rise to one third. Two out of every

three new power stations in the planning stage around the

globe will be environmentally sustainable plants.

Hybrid power stations will play an important role. “They com-

bine a heat source, such as a furnace using a fossil fuel, with

a sustainable energy source in order to increase the time

it is able to generate electricity,” explains Anton Neuhäuser

from the Fraunhofer Institute for Solar Energy Systems in the

southern German city of Freiburg im Breisgau.

From a technological standpoint, a whole range of different

hybrid models is available for different locations. In coastal or

wind-rich areas inland, electricity is generated by wind tur-

bines. In sunny countries, photovoltaic cells produce elec-

tricity directly from sunlight while solar thermal power sta-

tions produce steam that in turn drives turbines to generate

electricity. If output from sustainable sources declines due to

calm or cloudy conditions, the integrated gas or oil burner

ignites and prevents any drop-off in supply. In some coun-

tries, biomass is also being used. This is either converted

into methane or burnt directly, driving turbines to generate

electricity. Here, too, conventional energy sources such as

diesel, natural gas or oil plug the gap when the supply of bio-

22_25_Hybrid.indd 23 30.04.14 13:51

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ince its market launch in 2004, VARIOS has

been the bestselling FiFo reservoir for ciga-

rettes and filter rods. Operating between the

manufacturing line and the downstream pro-

duction stage, the new VARIOS-V serves as

a massflow reservoir adapting flexibly to the volume and

thereby enabling production to continue even if a machine

goes off-line. The FiFo principle again ensures that the cur-

ing times for filter rods remain constant and that cigarettes

are forwarded immediately and traceably. Different versions

of the VARIOS-V offer five, seven or nine levels that transport

between 100,000 and 200,000 cigarettes or filter rods.

Integrated, improved RTS-V

“One of the differences between this

model and its predecessor is the inte-

grated rod transfer system (RTS-V),

which is extremely efficient. It links the

reservoir of the VARIOS-V with other

machines and achieves a massflow

of 20,000 rods per minute. But it also

ensures that the transport process

is extremely gentle,” says Andreas

Schönberg, Technical Project Man-

ager who immediately points out

another advantage. “The infeed and

discharge modules can be posi-

tioned flexibly on the reservoir so the

VARIOS-V adapts perfectly to fit in

with existing production conditions.”

s

With a uniquely variable layout, low installation height and – for the first time – optional Quick size change, The VARIOS-V continues the tradition of its popular predecessor. and the new model now offers even greater product flexibility and protection.

even greater flexibility

VARios-V achieves a massflow of 20,000 rods per minute

and ensures that the transport is extremely gentle.

Format change in record time

The new system also offers manufacturers greater flexibility

in terms of product length. “Quick Size Change (QSC) is an

optional feature unique to the VARIOS-V. In older models, it

could take anything up to a week to adjust a machine to a

different format manually. But the VARIOS-V does the job in

under 30 minutes,” says Sven Wechsel, Product Consultant

at Hauni Engineering. Hauni has already received large num-

bers of orders for the VARIOS-V and some customers will

immediately equip their production lines with several of these

new reservoirs. The first units are due to be delivered in the

coming months.

34_35_VARIOS_V_ANZEIGE.indd 34 30.04.14 13:56

www.hauni.com

HAUNI IS THE RELIABLE PARTNER TO THE TOBACCO INDUSTRY. Thanks to solid engineering that has stood the test of time, our primary and secondary equipment is highly dependable and effi cient as well as easy to operate and maintain. It is always reassuring to know that Hauni machinery runs like clockwork. Let Hauni‘s new video show that you can rely on us. Go to www.hauni.com or simply scan the QR code.RELIABILITY – MADE BY HAUNI

YOU CAN RELY ON US:SEE THE HAUNI VIDEO

View by SmartPhone scan

HiLite_TZ-Video_KDF_2014.indd 1 12.03.2014 09:55:55

mass is not sufficient. “Technologically, there are no limits to

hybrid power stations – the restrictions are more commonly

economic,” says Neuhäuser, the Fraunhofer researcher.

“Power plants of this type are only economically viable when

they exceed a certain size or couple electricity production

with the use of the heat they generate as process heat and

cold or for the desalination of seawater. But because these

technologies are still relatively young, it is difficult to finance

the large, efficient plants necessary.”

The cost of the power plant is not the only factor that deter-

mines the price. System and infrastructure costs are also im-

portant: connections to electricity and gas grids, switchgear,

storage and control technology. This is where hybrid plants

show off their advantages. Operating several types of power

plant in one location increases the efficiency of each system

and reduces electricity generation costs.

hybrids replace infrastructure projects

In Europe, hybrid power stations are primarily designed to

guarantee reliable electricity supplies. Here, the energy shift

is in full swing. Renewables are replacing conventional gas,

coal and nuclear power stations. Economic growth is weaker

than in industrializing countries, the energy savings through

improvements in efficiency are higher – energy demand is

growing at a correspondingly low rate. “In Europe, the costs

are not so much associated with the construction of new

power stations but rather with financing the decommission-

ing of existing capacities,” says Maria van der Hoeven, Direc-

tor of the International Energy Agency (IEA).

he technological hurdles of integrating sus-

tainable and conventional energy sources

in Europe are also significant. Every wind

turbine, every roof fitted with solar panels,

every biogas plant and hydroelectric power

station now supplies power to a grid that was never de-

signed for these small-scale inputs. And the number of elec-

tricity generators is growing constantly.

In order to accommodate all these sources of electricity, the

grids must be upgraded. Electrotechnical construction pro-

grammes with budgets of billions aim to reduce the over-

all network load and balance bottlenecks in one area of the

country with overcapacity in another. Intelligently planned

hybrid power stations could assume vital roles in this new in-

frastructure. In many areas of Scandinavia, hybrid plants us-

ing biodiesel and wind power supply even the more remote

villages and islands with electricity. This eliminates the need

to extend power grids to the very ends of the fjords. Hybrid

plants coupling wind power with a gas burner to compen-

sate for fluctuations in the strength of the wind are also oper-

ational in Germany. With precisely regulated systems and in-

telligent storage, they guarantee a steady supply.

the trend: upgrading to hybrids

The concept of these interlinking systems shows great

promise. Around the world – in Russia, the USA, Indone-

sia, Latin America and Africa – a growing number of hybrid

power plants are being connected to the grid or are in the

planning stage. The up-and-coming industrial nations of Af-

rica, Latin America and Asia are setting the pace. They want

to upgrade existing conventional power stations with new

components in order to satisfy the rising demand for elec-

tricity in their booming industries and among their growing

populations. “This movement may have started in Europe,

but the rise of renewable energies has long ceased to be a

purely European story,” says IEA Director van der Hoeven.

t

Technologically, there are no limits to hybrid power stations – the restrictions are more commonly economic.”

“

Links:

www.iea.org/etp/

http://goo.gl/zHbew3

www.galapagoswind.org

electricityhydrogenheatbiogasgas mix

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22_25_Hybrid.indd 24 30.04.14 13:51

In the vincity of Berlin, germany’s first hybrid power plant is located (top left): It converts the power from wind turbines into

hydrogen, which can be converted back into electricity and long-distance heat combined with biogas in a cogeneration unit.

Thus, electricity flows even in the doldrums. In strong winds, electricity can be stored as hydrogen or used for fueling vehicles.

The system also works with solar panels instead of wind turbines producing electricity.

biogas plant

cogeneration unit

mixing valve

solar panels

wind turbine

grid

long-distance heat

hydrogen station

hydrogen storage

hydrogen generation

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22_25_Hybrid.indd 25 30.04.14 13:51

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Here is a selection of � lter designs that you can produce by using Hauni makers and modules.

All from one source

40 years of experience

All designs and formats

To get your free folder

please contact:

[email protected]

hn-anzeige_HiLiTE_rz.indd 2-3 23.04.14 20:36dw_anz_240x310_AZ_Hauni.indd 26 29.04.14 17:35

40


All from one source




please contact:

[email protected]


40


All from one source




please contact:

[email protected]

hn-anzeige_HiLiTE_rz.indd 2-3 23.04.14 20:36

40


All from one source




please contact:

[email protected]


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Recent years have seen the cigarette industry focus increasingly on The FilTer, with manufacturers looking to give their product an unmistakable appearance using innovative ideas. hauni offers perfect technical solutions for innovations like this.

UniqUesolutions

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Recent years have seen the cigarette industry focus increasingly on The FilTer, with manufacturers looking to give their product an unmistakable appearance using innovative ideas. hauni offers perfect technical solutions for innovations like this.

UniqUesolutions

28_33_FILTER-SNUS.indd 28 30.04.14 14:10

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he small part at the mouth end of a cig-

arette can be modified by adding new

flavours and giving it new functions and

a different “look-and-feel”. With so much

variety being added to filters, the possi-

bilities seem endless as the trend continues. As always,

Hauni keeps an ear to the ground and has harnessed the

creativity of its developers to devise perfect technical solu-

tions that will give manufacturers the versatility they need

to launch high-quality innovations speedily on the market.

KDF 5: The basic uniT For innovaTive FilTers

With its four decades of experience in filter making ma-

chinery, Hauni has designed its KDF 5 with the industry’s

future needs in mind. The machine is a basic unit which

makes acetate filters at a rate of 500 m/min, combining all

the best features of previous filter makers. KDF 5 is a safe

investment for the future, being highly cost-effective with

a unique choice of options which give it the flexibility to

adjust easily to whatever manufacturing process is being

run. Options as LEAD and FLEXPORT make it particularly

versatile in regards to rapid size changing and the produc-

tion of special filters.

lEAD: Changes length and diameter in record time

Faced with a changing production environment, the ciga-

rette industry has been asking for machinery that offers them

more flexibility. “Today‘s machines not only need to be ex-

tremely efficient, they also have to be designed to switch

quickly between different product specifications like material

and geometry,“ says Arne Klisch, Hauni Product Consulting.

Even in its basic version, the KDF 5 has been designed to

support manual changes in the geometry of the final product

with exchange of components and conversion of subas-

semblies and is considerably simpler than the previous and

more time-consuming filter makers. There are also options

available for increasing the level of automation and flexibili-

ty through LEAD – that stands for “length and diameter”. It

allows the operator to change these specifications in record

time at the touch of a button. The process has been acceler-

ated by eliminating screw-type connections, changing to

direct drives and devising an intelligently automated calibra-

tion process. The LEAD option is available exclusively for the

KDF 5 and increases the flexibility of the filter maker in hand-

ling different diameters and lengths by permitting automatic

or semi-automatic format changes.

“This solution offers our customers the non-plus-ultra in

terms of format changes,” says Klisch. “It cuts the time re-

quired to change the length from under 45 minutes in the ba-

sic version of the machine to less than 15 minutes. Changing

both length and diameter takes just under five hours in the

...KDF 5 is a safe investment for the future with the flexibility to adjust easily to whatever manufacturing process is being run.

T unique length and diameter flexibility

< 15min

< 1h

< 1h

< 45min

< 4h

< 5h

length

diameter

diameter and length

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standard version of the KDF 5. LEAD is capable of reducing

this to under one hour. The duration of format changes is

measured from stop of production to reaching quality pro-

duction again after a change.”

FleXPorT grows as ProDucTs DeveloP

Current efforts in the field of filter making are now being di-

rected towards increasing variety. The very name FLEXPORT

says what this platform does: it has been designed by Hauni

as a modular system that will respond to the market‘s need

for extreme flexibility with rapid function changing to maximi-

ze convertibility on modern filter makers.

LEXPORT consists of a basic module with

universal interfacing. Its function modules are

interchangeable to allow the unit to accept

any new modules which may subsequently

be designed to make other special-type filters

and individual filter designs. The basic module fits between

the tow processor and the rod maker with a function module

placed inside. “We’re continuing to expand this system on

an ongoing basis,” says Klaus Masuch, Group Manager in

Product Consulting. “At the moment we have three techni-

cally advanced modules available for FLEXPORT – Channel

Ventilation, Granule Application and Thread Application.”

FlEXPoRt-GA: Granules to suit all tastes

Apart from allowing the taste of the cigarette to be varied,

granules could also have a positive influence on the smoke

characteristics. It appears likely that the market will soon turn

to exploiting their potential more extensively in preference to

the usual charcoal as a way of making products more distinc-

tive. “The Granule Application Module which we designed for

FLEXPORT now makes it possible to add granules to filters in

far higher quantities. We offer the technology our customers

are going to need for their innovative designs,” says Masuch.

FlEXPoRt-CV: Channel Ventilation Module

Developers at Hauni adopted a similarly forward-looking

approach in designing their Channel Ventilation Module.

This FLEXPORT-CV module is designed for plasticized ace-

tate filters enclosed in an embossed semi-crepe paper inner

wrap and allows manufacturers to get new products ready

for launching in the shortest possible time. These filters have

a larger surface area to improve their filtering capabilities. As

the smoke is drawn through the filter, it takes the path of

least resistance via the channels, passing through the paper

at the fluted end. The flutes exhibit the same filtering proper-

ties whether they are positioned at the mouth end for dis-

tinctive appearance or hidden from view at the tobacco end.

This can be used either to give the cigarette smoking char-

acteristics similar to a monoacetate filter but with higher re-

tention, or the same retention with a lower pressure drop.

“The CV module allows to perform a high speed online em-

bossing process, so customers can give full rein to their

creativity,” says Masuch. “Of course an online measuring

unit called OCM-CV is available to provide the sensing ca-

pabilities which a fully fledged system needs to monitor pro-

duction.”

FlEXPoRt-tA: Flexible flavour unit

FLEXPORT’s Thread Application Module has also been de-

signed with the flexibility factor in mind. This versatile flavour

unit adds a new dimension to the range of flavours possible

FLEXPORT has been designed as a modular system for extreme flexibility with rapid function changing to maximize convertibility on modern filter makers.

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standard version of the KDF 5. LEAD is capable of reducing

this to under one hour. The duration of format changes is

measured from stop of production to reaching quality pro-

duction again after a change.”

FleXPorT grows as ProDucTs DeveloP

Current efforts in the field of filter making are now being di-

rected towards increasing variety. The very name FLEXPORT

says what this platform does: it has been designed by Hauni

as a modular system that will respond to the market‘s need

for extreme flexibility with rapid function changing to maximi-

ze convertibility on modern filter makers.

LEXPORT consists of a basic module with

universal interfacing. Its function modules are

interchangeable to allow the unit to accept

any new modules which may subsequently

be designed to make other special-type filters

and individual filter designs. The basic module fits between

the tow processor and the rod maker with a function module

placed inside. “We’re continuing to expand this system on

an ongoing basis,” says Klaus Masuch, Group Manager in

Product Consulting. “At the moment we have three techni-

cally advanced modules available for FLEXPORT – Channel

Ventilation, Granule Application and Thread Application.”

FlEXPoRt-GA: Granules to suit all tastes

Apart from allowing the taste of the cigarette to be varied,

granules could also have a positive influence on the smoke

characteristics. It appears likely that the market will soon turn

to exploiting their potential more extensively in preference to

the usual charcoal as a way of making products more distinc-

tive. “The Granule Application Module which we designed for

FLEXPORT now makes it possible to add granules to filters in

far higher quantities. We offer the technology our customers

are going to need for their innovative designs,” says Masuch.

FlEXPoRt-CV: Channel Ventilation Module

Developers at Hauni adopted a similarly forward-looking

approach in designing their Channel Ventilation Module.

This FLEXPORT-CV module is designed for plasticized ace-

tate filters enclosed in an embossed semi-crepe paper inner

wrap and allows manufacturers to get new products ready

for launching in the shortest possible time. These filters have

a larger surface area to improve their filtering capabilities. As

the smoke is drawn through the filter, it takes the path of

least resistance via the channels, passing through the paper

at the fluted end. The flutes exhibit the same filtering proper-

ties whether they are positioned at the mouth end for dis-

tinctive appearance or hidden from view at the tobacco end.

This can be used either to give the cigarette smoking char-

acteristics similar to a monoacetate filter but with higher re-

tention, or the same retention with a lower pressure drop.

“The CV module allows to perform a high speed online em-

bossing process, so customers can give full rein to their

creativity,” says Masuch. “Of course an online measuring

unit called OCM-CV is available to provide the sensing ca-

pabilities which a fully fledged system needs to monitor pro-

duction.”

FlEXPoRt-tA: Flexible flavour unit

FLEXPORT’s Thread Application Module has also been de-

signed with the flexibility factor in mind. This versatile flavour

unit adds a new dimension to the range of flavours possible

FLEXPORT has been designed as a modular system for extreme flexibility with rapid function changing to maximize convertibility on modern filter makers.

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The Channel Ventilation Module: Designed to perform a high-speed

online embossing process.

Flexport – CV Flexport – tA Flexport – GAThe Thread Application Module: Designed to add a variety of flavours

to the final product.

The Granule Application Module: Designed to add granules to filters in

far higher quantities.

28_33_FILTER-SNUS.indd 31 05.05.14 11:36

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Hauni has evolved two modules for the KDF 2ER for making hollow filters with variously shaped cavities.

KDF 2er: nwP + nwT Turn iDeas inTo realiTy

More flexible solutions are available in the shape of two mod-

ules called NWP and NWT. Developed for KDF 2ER, they

went into series production at the end of March. As an all-

rounder, KDF 2ER can make standard acetate filters as well

as hollow or shaped filters. Developers at Hauni have e-

volved the two modules for making hollow filters with variously

shaped cavities to allow manufacturers to give their products

an individualized appearance whilst obtaining a variety of

functional effects too. Currently Hauni is the only supplier of-

fering both systems for making hollow filters.

nWP: the pull principle

The NWP module is located between the AF-D dual tow pro-

cessing unit and the KDF 2ER rod maker. It runs at rates up to

300 m/min, producing non-wrapped smooth-surface filters

lacking the otherwise typical garniture tape pattern. This mod-

ule operates according to the pull principle: the KDF pulls

the two webs through the entire production process. The ace-

tate webs, which have both been previously sprayed and pro-

cessed, come together on the delivery roller on the dual-web

AF. The air in the transport jet then guides them evenly round

the shaper die, producing a pre-formed filter rod which is

pulled through the steam nozzle and then cooled and dried

by cooling jets. Despite the high manufacturing speed, cus-

tomers can still depend on obtaining filters of the usual high

Hauni standard. The system has an integrated online mon-

itor to check for the existence and position of the hollow

shape as well as any deformation in the finished filter.

nWt: the tamping principle of taste

The NWT module is located between the single-web AF 2ER

tow processing unit and the KDF 2ER. Unlike NWP, it tamps

the material, producing shaped and standard non-wrapped

filters at speeds which, depending on what material is used,

can range up to maximum machine speed.

“The KDF 2ER’s modular design means it can also process

different tows to produce two-colour or multiple-function fil-

ters. The filter maker gives customers a head start in pre-

paring themselves for tomorrow’s innovative filter scenario,”

says Andreas Johannsen, Product Manager Filter Making

Equipment & Logistic-Systems.

in the finished cigarette. Aromatic substances like menthol

can be added, cold or hot, either by spraying the tow or by

inserting a thread, offering a wide variety of taste options

that can be created without slowing production down. The

thread can be individually positioned as required and it is

also possible to insert more than one.

Detail of the AF-D dual tow processing unit: The acetate webs, which have both been previously

sprayed and processed, come together on the delivery

roller on the dual-web AF.

...

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Hauni has evolved two modules for the KDF 2ER for making hollow filters with variously shaped cavities.

KDF 2er: nwP + nwT Turn iDeas inTo realiTy

More flexible solutions are available in the shape of two mod-

ules called NWP and NWT. Developed for KDF 2ER, they

went into series production at the end of March. As an all-

rounder, KDF 2ER can make standard acetate filters as well

as hollow or shaped filters. Developers at Hauni have e-

volved the two modules for making hollow filters with variously

shaped cavities to allow manufacturers to give their products

an individualized appearance whilst obtaining a variety of

functional effects too. Currently Hauni is the only supplier of-

fering both systems for making hollow filters.

nWP: the pull principle

The NWP module is located between the AF-D dual tow pro-

cessing unit and the KDF 2ER rod maker. It runs at rates up to

300 m/min, producing non-wrapped smooth-surface filters

lacking the otherwise typical garniture tape pattern. This mod-

ule operates according to the pull principle: the KDF pulls

the two webs through the entire production process. The ace-

tate webs, which have both been previously sprayed and pro-

cessed, come together on the delivery roller on the dual-web

AF. The air in the transport jet then guides them evenly round

the shaper die, producing a pre-formed filter rod which is

pulled through the steam nozzle and then cooled and dried

by cooling jets. Despite the high manufacturing speed, cus-

tomers can still depend on obtaining filters of the usual high

Hauni standard. The system has an integrated online mon-

itor to check for the existence and position of the hollow

shape as well as any deformation in the finished filter.

nWt: the tamping principle of taste

The NWT module is located between the single-web AF 2ER

tow processing unit and the KDF 2ER. Unlike NWP, it tamps

the material, producing shaped and standard non-wrapped

filters at speeds which, depending on what material is used,

can range up to maximum machine speed.

“The KDF 2ER’s modular design means it can also process

different tows to produce two-colour or multiple-function fil-

ters. The filter maker gives customers a head start in pre-

paring themselves for tomorrow’s innovative filter scenario,”

says Andreas Johannsen, Product Manager Filter Making

Equipment & Logistic-Systems.

in the finished cigarette. Aromatic substances like menthol

can be added, cold or hot, either by spraying the tow or by

inserting a thread, offering a wide variety of taste options

that can be created without slowing production down. The

thread can be individually positioned as required and it is

also possible to insert more than one.

Detail of the AF-D dual tow processing unit: The acetate webs, which have both been previously

sprayed and processed, come together on the delivery

roller on the dual-web AF.

...

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oose snus is ground tobacco mixed with wa-

ter, salt and flavourings. The consumer takes a

pinch of tobacco, shapes it and places it un-

der his or her upper lip. The product traces its

roots back to Scandinavia’s fishermen. Naked

flames were prohibited on board their wooden boats and they

needed both hands free to work in the rough northern seas.

Today, loose snus can not only be found in the breast pocket

of a hardy fisherman but also in the inside pocket of a tuxedo

or a handbag chosen to match a stylish evening dress.

“Hauni already has many years of experience in processing

portioned snus. We are now focusing our energies on an-

other area – loose snus,” says Christofer Overbeck, Manager

Alternative Tobacco Products (ATP) at Hauni. “Until now, no

one has yet built a filling plant. We decided to plug this gap

in the market,” says the engineer.

Overbeck and his team have been working on the

FILLUTION-LTF80 ever since. At its heart lies a roller module

comprising a combing and a picker roller. Above the rollers,

there is a mixing tray from which the loose snus is spread

into the picker roller. The combing roller turns in the opposite

direction and combs the snus out of the recesses.

“This technology allows us to meter and package the product

very precisely; the discrepancies in weight have been meas-

ured at between just 1% and 2%,” says Overbeck. “This

figure was previously much higher than 10%.” These low

discrepancies in weight mean that the FILLUTION-LTF80

complies with new legal regulations. Customers also benefit

from significant cost savings due to the minimal standstills

and downtimes.

“The eight metering units operate independently of each

other so that if one fails, the plant continues to operate

but with a reduced number of modules,” says the Project

Manager. Metering units, rollers and cover plates are also

simple and quick to remove and wash with warm water

without the need for special tools.

packaging to the

last gram

hauni launches a pioneering new tech-nology – the FilluTion-lTF80 plugs a gap in the snus production process for which there was previously no automated solution.

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coming months.


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www.hauni.com

HAUNI IS THE RELIABLE PARTNER TO THE TOBACCO INDUSTRY. Thanks to solid engineering that has stood the test of time, our primary and secondary equipment is highly dependable and effi cient as well as easy to operate and maintain. It is always reassuring to know that Hauni machinery runs like clockwork. Let Hauni‘s new video show that you can rely on us. Go to www.hauni.com or simply scan the QR code.RELIABILITY – MADE BY HAUNI

YOU CAN RELY ON US:SEE THE HAUNI VIDEO

View by SmartPhone scan

HiLite_TZ-Video_KDF_2014.indd 1 12.03.2014 09:55:55

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analysts’heaven –

part two

uality is quantifiable. Hauni has always under

stood the vital importance of quality control

and assurance for its machines and services.

The unwavering objective is to deliver to the

customer a perfectly functioning product.

Hauni’s customers share this ambition so the metrology spe

cialists at Sodim and Borgwaldt KC offer a range of instru

ments that enable them to test and guarantee the quality of

Instruments from Sodim and Borgwaldt KC allow hauni to offer a broad portfolio of test stations for quality control of cigarettes and filter rods. their remarkable versatility enables every customer to tailor a test station to his own requirements.

Q

their products. These include test stations for quality control

of cigarettes and filter rods. The aim is to offer every custo

mer a test station tailored to his own specific requirements.

SodiQUBE and omi+: Fast measurements for lab-

oratory and production environments

For basic measurements, customers can choose between

the SODIQUBE test station from Sodim and the OMI+ from

Borgwaldt KC.

The SODIQUBE and OMI+ contain measurement modules

for the key parameters of weight, diameter/circumference,

pressure drop and ventilation, which qualifies them for use

not only in the laboratory but also in production environ

ments. An optional length module is available for both in

struments. Both instruments impress customers with their

sleek design, small footprint and userfriendly features.

omi-FlEX: test station with combinable modules

Customers seeking greater flexibility and customization in the

measurement parameters favour the OMIFLEX. The meas

oMi-FLEX: The measurement station offers nine combin

able modules for a variety of parameters.

36_37_ANALYSTS.indd 36 05.05.14 11:34

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analysts’heaven –

part two

uality is quantifiable. Hauni has always under

stood the vital importance of quality control

and assurance for its machines and services.

The unwavering objective is to deliver to the

customer a perfectly functioning product.

Hauni’s customers share this ambition so the metrology spe

cialists at Sodim and Borgwaldt KC offer a range of instru

ments that enable them to test and guarantee the quality of

Instruments from Sodim and Borgwaldt KC allow hauni to offer a broad portfolio of test stations for quality control of cigarettes and filter rods. their remarkable versatility enables every customer to tailor a test station to his own requirements.

Q

their products. These include test stations for quality control

of cigarettes and filter rods. The aim is to offer every custo

mer a test station tailored to his own specific requirements.

SodiQUBE and omi+: Fast measurements for lab-

oratory and production environments

For basic measurements, customers can choose between

the SODIQUBE test station from Sodim and the OMI+ from

Borgwaldt KC.

The SODIQUBE and OMI+ contain measurement modules

for the key parameters of weight, diameter/circumference,

pressure drop and ventilation, which qualifies them for use

not only in the laboratory but also in production environ

ments. An optional length module is available for both in

struments. Both instruments impress customers with their

sleek design, small footprint and userfriendly features.

omi-FlEX: test station with combinable modules

Customers seeking greater flexibility and customization in the

measurement parameters favour the OMIFLEX. The meas

oMi-FLEX: The measurement station offers nine combin

able modules for a variety of parameters.

36_37_ANALYSTS.indd 36 05.05.14 11:34

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soDiLinE family: The instrument group now comprises six

test stations with between one and six modules.

urement station offers nine combinable modules for a va

riety of parameters including hardness, moisture and sort

ing. “All of these modules are selfcontained measurement

units and can be operated either as a single measure

ment station or in any multiple combination,” says Michael

Connor, Managing Director of Borgwaldt KC, Richmond,

US. “Moreover, the modules can be integrated into any

other OMIFLEX station.” This is all possible in a station

with an even smaller footprint than that of the OMI+.

SodilinE: test stations with maximum flexibility

The revised and optimized SODILINE family offers maxi

mum flexibility. “It is ten years since SODILINE was first

launched onto the market. This seemed like a good rea

son to overhaul and relaunch the range,” says Eric Favre,

Managing Director at Sodim. “We have optimized the de

sign of the measurement instruments and made them more

modular than ever before.

“Instead of four models, SODILINE now comprises six

test stations with between one and six modules; these are

smaller and more compact than their predecessors. If they

wish, customers can also supplement each model with

one additional module at a later date. We offer a choice of

15 modules,” says Favre. All existing SODILINE measure

ment modules can still be used with the new SODILINE

family.

This portfolio of products from Sodim and Borgwaldt KC

offers customers a range of customized solutions for every

task – both today and in the future.

„We have optimized the design of the measurement instruments and made them more modular than ever before.”

36_37_ANALYSTS.indd 37 05.05.14 11:34

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Primaryservices

in big demand

Offering a choice of services including inspection, overhauling, upgrading and relocation, hauni’s Primary service team is ready for action 365 days a year. clients benefit from their experience, accuracy and punctuality.

38_39_Primary_Service.indd 38 30.04.14 13:59

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Primaryservices

in big demand

Offering a choice of services including inspection, overhauling, upgrading and relocation, hauni’s Primary service team is ready for action 365 days a year. clients benefit from their experience, accuracy and punctuality.


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anything from replacing the SRE anchor bridge for a vibra-

tory conveyor to full-scale relocation plus commissioning.”

Relocation is such a major operation that it calls for practi-

cally everything the Primary Service team has to offer. An

extremely high level of know-how, accuracy and experience

is needed to ensure that moving single machines or an en-

tire primary is completed smoothly and within schedule.

The objective in such operations is to make sure that all the

jobs – from analyzing current status and future requirements,

dismantling the units, packing and transporting them safely,

right through to setting them up for production and recon-

figuring them to suit the new environment – are completed

within the shortest possible time.

Yet even with smaller orders, the team’s experience and

technical capability explain why it is so successful. “Custom-

ers who consult us always find a person who understands

their needs and can work out solutions to meet individual

requirements. That begins with our on-site inspection service

where our staff carry out a status analysis and then draw up

a made-to-measure quotation,” explains Kohlhardt.

Customers can also benefit from the Primary Service team’s

know-how in the shape of its modular customer training

scheme: “Courses are designed to suit the exact needs of

participants. They help to ensure an optimum manufacturing

process with maximum safety, less downtime, lower mainte-

nance times and better product quality, whether they’re us-

ing newly purchased machines or running an existing setup,”

says Kohlhardt.

ast June Hauni’s Primary Service was called

out to the Shanghai Cigarette Factory. In just

eight days the team managed to carry out a

full overhaul of a KLK cylinder drier, bringing

it up to the most modern technical standard

to enable the factory to continue running the unit efficiently.

This was not the first time that Mr Ye Shen, Vice Chief of Pri-

mary workshop of Shanghai CF, had enlisted the help of the

Primary Service team. In 2012 it had replaced the entire top

section of an HT conditioner in a record two days (see insert).

“We are satisfied about the success of the overhauls regard-

ing the reliability of the machines and the product quality,”

says Ye. That is what Hauni intended to achieve with its range

of Primary Services which has seen steady expansion.

The growing team provides services to meet manufactur-

ers’ needs throughout the entire lifecycle of their machinery.

The options include upgrades to bring older units into line

with modern technology and overhauls to restore a machine

to its original state – the Primary Service team is available

365 days a year. “We’ve seen an increasing demand for our

Services,” comments Ralf Kohlhardt who is in charge of the

team. “Our customers call us because they know they’ll al-

ways find a capable person here who also has the technical

competence to help with a problem – and that can mean

l

HT conditioner overhaul is a popular Hauni Primary Services,

with over 600 sold to date. After years of reliable operation

the extreme stress caused by heat and vibration can eventu-

ally lead to signs of material fatigue in the top section of

the HT. The benefit of replacing it with a fully preassembled

unit include:

only one to two days’ downtime before resuming operation

with a practically new machine,

top quality and long service life due to preassembly in

optimum conditions,

plus the option to upgrade to state-of-the-art technology.

as fast as new: Ht conditioner overhaul


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the hauni Webshop has become an important tool – and not just for purchasers. Engineers and technicians also use it to find customized, real time information that makes their work easier.

MorE Thanan ordEring

platform

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8

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9

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a universal tool which allows customers to: 1. order machine parts 2. personalize accounts 3. optimize data protection

4. track & trace outstanding orders 5. give priority to urgently required parts 6. enter own part numbers and add them to docu-

ments 7. quickly identify needed parts 8. use online documents that reflect all changes made to machinery 9. access information

anytime and anywhere 10. use an online always up-to-date archive with individualized data.

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the hauni Webshop has become an important tool – and not just for purchasers. Engineers and technicians also use it to find customized, real time information that makes their work easier.

MorE Thanan ordEring

platform

1

8

6

7

9

10

a universal tool which allows customers to: 1. order machine parts 2. personalize accounts 3. optimize data protection

4. track & trace outstanding orders 5. give priority to urgently required parts 6. enter own part numbers and add them to docu-

ments 7. quickly identify needed parts 8. use online documents that reflect all changes made to machinery 9. access information

anytime and anywhere 10. use an online always up-to-date archive with individualized data.

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rom track & trace and individual part designa-

tions to supplementary product information and

current machinery documentation – the Hauni

Webshop has been enriched by many addition-

al functions. Today, it has outgrown its original

concept as the central ordering platform for machine parts, it

is also a comprehensive source of information and data. This

now makes it an interesting tool not just for purchasers, but

for technicians, engineers and logistics specialists. They use it

to access an extensive range of services, which are adapted

to their specific fields and significantly simplify their processes.

Employees register in the Webshop using their user profiles.

“Each login is via a personalized account so our customers

decide who has access to which pages,” says Maik Freschke,

Project Manager Hauni Administration Services, explaining the

access concept. “The profiles are set up so that each employ-

ee only has access to the areas relevant to his or her work. All

other data continues to have the optimum protection.”

the most important new features in the hauni Webshop:

track and trace in real time

The track & trace function gives a clear overview of all outstand-

ing orders in a single list. This provides the order status for eve-

ry product – not only for orders placed by customers but also

for spare parts supplied by Hauni within the framework of its

service contracts. Goods can be tracked precisely en route to

their destinations. Receiving departments are therefore infor-

med well in advance about all incoming deliveries and can, for

example give priority to urgently required parts. This, in turn,

enables customers to deploy and coordinate their technicians

with greater efficiency. The track & trace system creates trans-

parency and increases planning reliability.

individual product designations

When naming spare parts, customers often use their own part

numbers. To save time and prevent confusion, Hauni offers a

special service: the customer’s material numbers can be en-

tered into a database. Corresponding customer product de-

signations are added not only to the sales and customs do-

cuments but also to the pick labels. The result: employees

who are familiar with these internal designations find their way

around more quickly and the customer is able to work with his

own material numbers in his logistics.

background information about spare parts

The “paper clip” icon in the Webshop now indicates that a great

deal of additional information is available about a product. By

clicking on product details, size and weight, customs informa-

tion is shown. Furthermore installation instructions and safety

information can be downloaded and is of particular interest to

engineers and technicians. “You can identify the machine that

a part is used in as soon as you click on the where-used-list.

Moreover, this is tailored to the individual customer’s machine

park,” says Nils Kloth, Project Manager Hauni IT. “This gives our

customers the security of knowing that they really are ordering

the correct part.”

the latest information is always at your fingertips

Hauni supplies a DVD providing important technical information

with every machine. However, after a conversion, this informa-

tion often no longer reflects the latest alterations. For this rea-

son, all documents are now also available online and imme-

diately reflect the changes made to machinery. Consequently,

the data for engineers and technicians is always up-to-date

right down to the level of the individual part. Another advan-

tage: when information is available online, it can be accessed

anytime and anywhere. The customer no longer has to dedi-

cate time and resources to archiving this information.

F

You can identify the machine that apart is used in as soon as you click on the where-used-list – it is tailored to the individual customer’s machine park.”

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he night is nearly over and silence envelops

the rainforest, broken only by the occasion-

al chirping of the crickets. The first rays of

sunlight slant between wooden huts where

figures are gradually emerging into the cool

dampness of the early morning. Here in their camp on the

edge of the French-Guianan jungle, the day is just beginning

for a group of forest canopy researchers.

High temperatures and extreme humidity make it hard to

explore the rainforest. With trees up to 40 metres high, the

canopy is difficult to access. The first botanists climbed

their way to the treetops. By around 1950 metal towers

were appearing in several rainforests in an effort to make

access easier. Then cranes came into use. Walkways were

suspended beween treetops. Yet, useful as they were, none

of these had ever allowed the scientists to move above the

green canopy.

Biologist Francis Hallé is a professor emeritus at the Univer-

sity of Montpellier who specializes in rainforest research. His

expertise in this largely unexplored habitat has been gained

through years of laboratory work and numerous expedi-

tions to virgin rainforests. It was during a scientific expedition

with students that the vision of investigating the trees from

above began to form in his mind. “I realized I would never

know the rainforest properly till I had studied it from the top,”

recalls Hallé.

T

The greenFlighT To

canopyToo high, too deep, too far – there have always been obstacles on the road to scientific discovery. Yet technical progress is helping today’s pioneering minds to surmount the difficulties. Botanist Francis hallé hit on the idea of using an airship and an inflatable plastic raft in his bid to gain access to rainforest treetops.

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he night is nearly over and silence envelops

the rainforest, broken only by the occasion-

al chirping of the crickets. The first rays of

sunlight slant between wooden huts where

figures are gradually emerging into the cool

dampness of the early morning. Here in their camp on the

edge of the French-Guianan jungle, the day is just beginning

for a group of forest canopy researchers.

High temperatures and extreme humidity make it hard to

explore the rainforest. With trees up to 40 metres high, the

canopy is difficult to access. The first botanists climbed

their way to the treetops. By around 1950 metal towers

were appearing in several rainforests in an effort to make

access easier. Then cranes came into use. Walkways were

suspended beween treetops. Yet, useful as they were, none

of these had ever allowed the scientists to move above the

green canopy.

Biologist Francis Hallé is a professor emeritus at the Univer-

sity of Montpellier who specializes in rainforest research. His

expertise in this largely unexplored habitat has been gained

through years of laboratory work and numerous expedi-

tions to virgin rainforests. It was during a scientific expedition

with students that the vision of investigating the trees from

above began to form in his mind. “I realized I would never

know the rainforest properly till I had studied it from the top,”

recalls Hallé.

T

The greenFlighT To

canopyToo high, too deep, too far – there have always been obstacles on the road to scientific discovery. Yet technical progress is helping today’s pioneering minds to surmount the difficulties. Botanist Francis hallé hit on the idea of using an airship and an inflatable plastic raft in his bid to gain access to rainforest treetops.

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The botanist teamed up with Dany Cleyet-Marrel, a pilot, and

an inventor called Gilles Ebersolt. A few years later the three

went up in a hot-air balloon carrying a raft-like platform and

managed to set it down on top of the trees.

the treetop raft

On an open area, a team of six is unrolling a giant bag –

about fifty metres long. They attach an air pump and slowly

the bag takes on the shape of a zeppelin. With 8,500 m3

of air inside, the huge contraption is still recumbent but is

already 20 m high. Cleyet-Marrel, the pilot, walks round it

with a critical eye, then climbs into the gondola. He ignites

three burners and immediately the airship begins to right it-

self. Now it’s time to start preparing the raft.

The raft’s inventor is an architect. Gilles Ebersolt had already

created a stir by designing a giant air-filled “ballule” or zorb,

a vehicle that could roll downhill. When Hallé approached

him, he jumped at the chance of taking part. Ebersolt sub-

sequently devised a treetop raft – right now he is stand-

ing near the waiting airship and has begun pumping up the

raft’s tubes.

The raft is hexagonal in shape and features six of these

tubes, each 13.6 m long and 0.98 m in diameter. They meet

in the centre, forming six triangles which are covered with

black netting. The men are busy preparing the loops which

will be used to suspend the raft from the airship. Despite its

Together the blimp and the raft lift off and rise slowly – they are on their way to harvest on the canopy of the rainforest.

...

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diameter of 27 m and a total surface of nearly 600 m2, the

raft weighs no more than about 750 kilograms.

Ebersolt hooks the raft up to the gondola. Wearing a safety

helmet and carrying a walkie-talkie, the inventor now fastens

his safety belt and sits waiting in the centre of the raft for

the treetop flight to start. The blimp lifts off and rises slowly.

“Together the raft and the blimp add up to a load of over two

tonnes,” says Hallé.

Counting in nightingales

The upper weight limit was one of the biggest challenges fac-

ing Ebersolt when designing the raft. How big a load could

a forest canopy support? In the first draught he made on

paper the raft weighed 1.7 kilos per m2. “To get some idea

of how that load would affect the treetop canopy, I decided

to ditch kilograms and opted for a unit that would be more

compatible,” says Ebersolt. Birds seemed a good choice,

so he called his parameter “nightingale units”. The average

nightingale weighs 25 grams. To support a tree raft the can-

opy would need to be able to carry 68 times that weight – 68

fully grown nightingales per m2. It was a load you could visu-

alize, and practice later confirmed the theory.

The canopy raft made its first test flights under a hot-air bal-

loon in the south of France. The initial manoeuvres in Guiana,

however, soon showed Dany Cleyet-Marrel that although he

could set the raft down, the equatorial winds tended to blow

the balloon aside. So the balloon was replaced by a blimp.

This could hold its position above the raft and was also able

to carry heavier loads. The area of the raft was increased

once again.

The team funded their project by obtaining loans, selling me-

dia rights and by enlisting the assistance of investors. The

pharmaceutical industry showed interest in the research

results. Medically effective plants are known to grow in the

rainforest – it is a pharmacologist’s warehouse.

Botanical harvest: blossoms, fruit and leaves are collected and put in drying units on the work raft. Later these will be identified at universities’ herbaria.

...

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diameter of 27 m and a total surface of nearly 600 m2, the

raft weighs no more than about 750 kilograms.

Ebersolt hooks the raft up to the gondola. Wearing a safety

helmet and carrying a walkie-talkie, the inventor now fastens

his safety belt and sits waiting in the centre of the raft for

the treetop flight to start. The blimp lifts off and rises slowly.

“Together the raft and the blimp add up to a load of over two

tonnes,” says Hallé.

Counting in nightingales

The upper weight limit was one of the biggest challenges fac-

ing Ebersolt when designing the raft. How big a load could

a forest canopy support? In the first draught he made on

paper the raft weighed 1.7 kilos per m2. “To get some idea

of how that load would affect the treetop canopy, I decided

to ditch kilograms and opted for a unit that would be more

compatible,” says Ebersolt. Birds seemed a good choice,

so he called his parameter “nightingale units”. The average

nightingale weighs 25 grams. To support a tree raft the can-

opy would need to be able to carry 68 times that weight – 68

fully grown nightingales per m2. It was a load you could visu-

alize, and practice later confirmed the theory.

The canopy raft made its first test flights under a hot-air bal-

loon in the south of France. The initial manoeuvres in Guiana,

however, soon showed Dany Cleyet-Marrel that although he

could set the raft down, the equatorial winds tended to blow

the balloon aside. So the balloon was replaced by a blimp.

This could hold its position above the raft and was also able

to carry heavier loads. The area of the raft was increased

once again.

The team funded their project by obtaining loans, selling me-

dia rights and by enlisting the assistance of investors. The

pharmaceutical industry showed interest in the research

results. Medically effective plants are known to grow in the

rainforest – it is a pharmacologist’s warehouse.

Botanical harvest: blossoms, fruit and leaves are collected and put in drying units on the work raft. Later these will be identified at universities’ herbaria.

...

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reetop landing

A track leading from the camp to the raft’s

landing site is used to transport materials

which are too bulky for the zeppelin. Hallé

and his colleagues are now standing at the

foot of the trees where the raft is due to touch down. Far

aloft they can see the dense green canopy. A landing site

has been marked out with luminous tapes for easy location.

Meanwhile Ebersolt, seated on the raft, is preparing himself

for the landing. Cleyet-Marrel cautiously brings the airship

down, and the raft’s black netting settles over the curves of

the treetops. Ebersolt detaches the raft from the blimp and

it slowly moves away. Then he checks the security. The raft

will need to settle for a few hours before the researchers can

start their work.

scientists reap rich harvest

Finally the scientists can begin the climb. The group includes

foresters, entomologists, ornithologists, parasitologists and

geneticists. Using spikes and ropes, they make their way

up to the raft, blinking as they push their way through the

dark foliage into dazzling sunlight. The air is dry and the tem-

perature is close to 40° C. Hallé starts by making meticu-

lous drawings of the surrounding trees. Then the botanical

harvest begins: blossoms, fruit and leaves are collected and

put in drying units on the work raft. Later on these will be

sent to the world’s major university herbaria for identification

– Paris, London, Wageningen in the Netherlands and New

York. There are new discoveries in store for the fauna ex-

perts on the canopy raft too. Entomologists Gérard Delvare

and Henri Pierre Aberlenc collected so many insects here

that they needed months to classify them. They came across

many unusually large species which find the juiciest leaves at

the top of a tree.

A total of eight expeditions were undertaken between 1986

and 1999. There were twenty participants and fifty scientific

assistants who joined them from time to time. Assessing the

value of the material they collected is likely to take a long

time yet. In Hallé’s view, the rainforest is a habitat still full of

secrets whose significance for the life and health of humanity

is not yet fully appreciated. The acute threat to the rainforests

and their rapid disappearance, he says, can only be stopped

through intensive research.

T

Under observation: The wild tarsier

and the red-eyed tree frog are watch-

ing the researchers – foresters, en-

tomologists, ornithologists, parasitol-

ogists and geneticists – doing their job

on the treetops of the rainforest.

42_45_Baumwipfel.indd 45 30.04.14 14:01

300 dollars

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A housE for

some 100 million people around the world are homElEss. More than 1 billion live in substandard housing. cheap houses could offer a solution to the problem.

46_47_300_Dollar_Haus.indd 46 30.04.14 14:02

300 dollars

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A housE for

some 100 million people around the world are homElEss. More than 1 billion live in substandard housing. cheap houses could offer a solution to the problem.

46_47_300_Dollar_Haus.indd 46 30.04.14 14:02

300 dollarsFrom the townships of south Africa to the jhuggi slums of

new Delhi – the lack of available housing for the world’s

poorest people is a global problem. Vijay Govindarajan,

professor at the Tuck school of business in Dartmouth,

new Hampshire, Us, and marketing consultant Christian

sarkar decided to take action when they founded the

“$300 house project”. The initiative aims to develop ac-

commodation that can be built for less than Us$300,

shelters its inhabitants against the weather and provides

a sleeping place as well as running water and electricity.

Why target the figure of Us$300? international studies

show that people who have escaped the most serious

poverty typically live in dwellings valued at an average of

Us$370. The open design competition has so far received

300 submissions (see e.g. illustration). Two prototypes

have been built in Haiti using the best ideas. The next

phase is being planned – a model settlement in the earth-

quake devastated Caribbean nation. www.300house.com

Even insects and spiders have houses. Housing is a human right.”

Vijay Govindarajan

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hush falls over the hall when Arne Klisch

from Hauni Product Consulting demon-

strates the new KDF 5 to his customers.

"Not just because they are impressed

by the flexibility of our new filter maker,"

says Klisch. "They are immediately struck by the signifi-

cant reduction in machine noise comp ard tot h

Working together with the company's engineers, Hau-

ni's in-house noise protection expert has succeeded in

curbing the noise emissions of the KDF 5. In tests, in-

stead of the usual level for filter makers of around 85

dB(A), the KDF 5 achieved a level of just 74 dB(A) de-

pending on t h e .

"So what?" you may ask. But this rather unimpressive

sounding number actually reflects a remarkable differ-

ence. Differences of only 3 decibels (dB) are clearly dis-

tinguishable to the human ear and a reduction of 10 dB

in the noise level is perceived as a halvg of th e vol

Measuring as the ear hears

Hauni, too, uses the noise level measured in decibels as

the basis for its noise measurements in accordance with

the valid noise protection guidelines. It is defined as a

logarithmic unit expressing the relationship between the

measured sound pressure (Pa) and the reference sound

pressure of 20 µPa, which is set at the hearing thresh-

old level of 0 dB. As the human sense of hearing is not

equally sensitive to all frequencies, the levels measured

are adjusted using an evaluative filter. This takes into

account the frequency range of the human ear. As this

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“Not just because they are impressed by

the flexibility of our new filter maker,” says

Klisch. “They are immediately struck by the significant re-

duction in machine noise compared to other makers.”

Working together with the company’s engineers, Hauni’s

in-house noise protection expert has succeeded in curb-

ing the noise emissions of the KDF 5. In tests, instead of

the usual level for filter makers of around 85 dB(A), the

KDF 5 achieved a level of just 74 dB(A) depending on the

materials used.

“So what?” you may ask. But this rather unimpressive




in the noise level is perceived as a halving of the volume.










are adjusted using an evaluative filter. This takes into ac-

count the frequency range of the human ear. As this filter

A

Helicopter:

max. 115 dB(A)

Motor boat:

max. 110 dB(A)

Diesel engine:

max. 90 dB(A)

Hauni works continuously to cut tHe noise eMission of its machines – which makes a tangible contribution to the sustainability of its products. Low noise level starts its life in the design phase and Hauni customer employees are the long-term beneficiaries.

WHen A HusHfalls over the factory

48_49_LAERMSCHUTZ_neu.indd 48 30.04.14 14:04




"Not just because they are impressed

by the flexibility of our new filter maker,"

says Klisch. "They are immediately struck by the signifi-

cant reduction in machine noise comp ard tot h

Working together with the company's engineers, Hau-

ni's in-house noise protection expert has succeeded in

curbing the noise emissions of the KDF 5. In tests, in-

stead of the usual level for filter makers of around 85

dB(A), the KDF 5 achieved a level of just 74 dB(A) de-

pending on t h e .

"So what?" you may ask. But this rather unimpressive




in the noise level is perceived as a halvg of th e vol










are adjusted using an evaluative filter. This takes into

account the frequency range of the human ear. As this

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“Not just because they are impressed by

the flexibility of our new filter maker,” says

Klisch. “They are immediately struck by the significant re-

duction in machine noise compared to other makers.”

Working together with the company’s engineers, Hauni’s

in-house noise protection expert has succeeded in curb-

ing the noise emissions of the KDF 5. In tests, instead of

the usual level for filter makers of around 85 dB(A), the

KDF 5 achieved a level of just 74 dB(A) depending on the

materials used.

“So what?” you may ask. But this rather unimpressive




in the noise level is perceived as a halving of the volume.










are adjusted using an evaluative filter. This takes into ac-

count the frequency range of the human ear. As this filter

A

Helicopter:

max. 115 dB(A)

Motor boat:

max. 110 dB(A)

Diesel engine:

max. 90 dB(A)

Hauni works continuously to cut tHe noise eMission of its machines – which makes a tangible contribution to the sustainability of its products. Low noise level starts its life in the design phase and Hauni customer employees are the long-term beneficiaries.

WHen A HusHfalls over the factory


filter is generally A-weighted today, the sound pressure

level is usually stated in the unit( A

For Frank Dose, engineer in the Development divi-

sion, and Harald Otto-von der Heide, Quality Supervi-

sor Products/Final Inspection, these units are a familiar

part of everyday life. The two noise specialists are re-

sponsible for noise emissions in the development and

series production of Hauni machines. Noise protection

has been established in Hauni's development strategy

for more than 10 year.

the source and the propagation of sound

The two researchers work on primary and secondary

measures for reducing noise emissions. "By primary

measures, we mean everything that prevents the ma-

chine from making noise in the first place. For example,

we use direct drives in virtually all our M-generation ma-

chines," says Otto-von der Heide. "Whenever you elimi-

nate a gearbox from a design, the machine becomes

significantly quieter. For the KDF 5, we also incorpo-

rated another primary measure in the design phase – a

low vibration machine be"

Dose then explains that secondary measures comprise

all the features intended to prevent noise from escaping

and spreading. "The high quality seals we use today

are a good example of a secondary measure. We have

integrated many measures of this type especially in the

M-generation PROTOS machines. "

the beneficiaries: our customers' employees

For Sustainability Manager Dirk Kronenberg, this com-

mitment to noise reduction will remain a firm compo-

nent of Hauni's sustainability strategy. "We make our

products more sustainable wherever it serves the needs

of our customers. Reducing noise has a very positive

effect on the employees who work every day in the

production halls. It often allows them to work without

hearing protection, which is a legal requirement above a

noise level of 85 dB(A). They also suffer less stress due

to noise exposure in the wore

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is generally weighted based on area (A) today, the sound

pressure level is usually stated in the unit dB(A).

For Frank Dose, engineer in the Development division,

and Harald Otto-von der Heide, Quality Supervisor

Products/Final Inspection, these units are a familiar part

of everyday life. The two noise specialists are respon-

sible for noise emissions in the development and series

production of Hauni machines. Noise protection has

been established in Hauni’s development strategy for

more than ten years.

the source and the propagation of sound

The two researchers work on primary and secondary

measures for reducing noise emissions. “By primary

measures, we mean everything that prevents the ma-

chine from making noise in the first place. For example,

we use direct drives in virtually all our M-generation ma-

chines,” says Otto-von der Heide. “Whenever you elimi-

nate a gearbox from a design, the machine becomes

significantly quieter. For the KDF 5, we also incorporated

another primary measure in the design phase – a low

vibration machine bed.”

Dose then explains that secondary measures comprise

all the features intended to prevent noise from escap-

ing and spreading. “The high quality seals we use today

are a good example of a secondary measure. We have

integrated many measures of this type especially in the

M-generation PROTOS machines.”

the beneficiaries: our customers’ employees

For Sustainability Manager Dirk Kronenberg, this com-

mitment to noise reduction will remain a firm component

of Hauni’s sustainability strategy. “We make our prod-

ucts more sustainable wherever it serves the needs of

our customers. Reducing noise has a very positive effect

on the employees who work every day in the production

halls. It often allows them to work without hearing pro-

tection, which is a legal requirement above a noise level

of 85 dB(A). They also suffer less stress due to noise

exposure in the workplace.”

Diesel engine:

max. 90 dB(A)

Washing machine:

max. 78 dB(A)

Vacuum cleaner:

max. 81 dB(A)

KDF 5:

max. 74 dB(A)

Guess who is making more noise: Your vacuum

cleaner, your washing machine or Hauni’s KDF 5?


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moke has been a source of fascination

ever since man discovered how to use fire.

It has been used in ancient rituals and

ceremonies and even now is said to possess

spiritual and healing powers. American natives

used it to communicate, sending up smoke signals that

could be seen from afar. Quite a different kind of smoke sig-

nal was observed on the island of Sicily in November 2013

when Mount Etna not only spewed out fountains of lava but

also blew smoke rings skywards.

Smoke rings can measure up to 200 metres in diameter.

How they form is still a matter for conjecture, but experts

Sat least agree that the shape of the vent must play a role in

their formation. Their theory: If the opening is almost entirely

round in shape, the smoke in the middle of the vent could be

expelled faster than at its edges – forming a ring with its own

dynamics and energy system. If that is a correct assumption,

it would still require the smoke to be expelled in bursts and at

an appropriate speed.

Volcanic smoke rings are a rare natural phenomenon that

has been witnessed not only above Mount Etna but also over

Stromboli, another Italian volcano, as well as Eyjafjallajökull

in Iceand. Incidentally, even whales and dolphins sometimes

create similar water vapour rings when they breathe out.

Strange Smokesignals

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moke has been a source of fascination

ever since man discovered how to use fire.

It has been used in ancient rituals and

ceremonies and even now is said to possess

spiritual and healing powers. American natives

used it to communicate, sending up smoke signals that

could be seen from afar. Quite a different kind of smoke sig-

nal was observed on the island of Sicily in November 2013

when Mount Etna not only spewed out fountains of lava but

also blew smoke rings skywards.

Smoke rings can measure up to 200 metres in diameter.

How they form is still a matter for conjecture, but experts

Sat least agree that the shape of the vent must play a role in

their formation. Their theory: If the opening is almost entirely

round in shape, the smoke in the middle of the vent could be

expelled faster than at its edges – forming a ring with its own

dynamics and energy system. If that is a correct assumption,

it would still require the smoke to be expelled in bursts and at

an appropriate speed.

Volcanic smoke rings are a rare natural phenomenon that

has been witnessed not only above Mount Etna but also over

Stromboli, another Italian volcano, as well as Eyjafjallajökull

in Iceand. Incidentally, even whales and dolphins sometimes

create similar water vapour rings when they breathe out.

Strange Smokesignals


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Publisher: Hauni Maschinenbau AG Responsibility for content: Jörg Walter, Gitte Möller, Ute DahlenburgHauni Maschinenbau AGKurt-A.-Körber-Chaussee 8 - 32D-21033 HamburgTel.: +49 40 7250-2992Fax: +49 40 [email protected]

Publishing company:G+J Corporate Editors GmbH, Hamburg CEO: Soheil Dastyari, Stephan Schäfer. Publishing Manager: Jana Vosolil. Ad Sales: G+J Media Sales, Direct Sales.Executive Director Direct Sales: Heiko Hager, Tel. 040/3703-5300Advertising: Jan-Eric Korte, Alexandra Kolatzek, Tel. 040-3703-5308www.corporate-editors.com

Editor-in-chief: Torsten Engelhardtwww.toe-kom.de, Hamburg

Art direction: Matthias Welker claim GmbH, Hamburg

Articles authored by:Nicole Knabe, Mirjam Müller, Axel Novak, Dr. Martin Tschechne, Roxana Weißenberg

Translations: Lesley McArthur-Dreyer, Edward Westerdale

Lithography: Dunz-Wolff Mediendienst- leistungen GmbH, Hamburg

Printed by: Neef + Stumme premium printing GmbH & Co. KG, Wittingen

© May 2014Hauni Maschinenbau AG

Cover: CanStockPhoto/plinghoo P. 3: PRP. 4: Sebastian Vollmert l., KUKA Roboter GmbH (PR)P. 5: PR; Getty Images/Dorling Kin-dersley t.r., Frank Reinhold b.P. 6-7: Sebastian Vollmert P. 8-9: Meyer-Hayoz Design Enge-neering Deutschland (PR), KUKA Roboter GmbH (PR)P. 10-11: ICON Aircraft (PR), Still GmbH (PR)

P. 12-13: iStock Photo/Zhenikeyev+ mammamaart (Collage), PR P. 14-15: PR P. 16-17: Getty Images l., claim c., PR r. P. 18-21: Frank Rheinhold P. 22-23: Corbis Images/David Stoecklein l., action press/XinhuaP. 24: Rainer WeisflogP. 25: Erfurth Kluger Infografik P. 28-33: PR/Christian Geisler P. 34: PR

P. 36-37: Getty Images/Federica Grassi t., PR P. 38-39: Corbis Images/Chris Crisman P. 40-41: Shutterstock/Artur SynenkoP. 42-43: laif/Ocean VertP. 44-45: Corbis Images/Deddeda t.l., Focus/Science Photo Library/Philippe Psaila b.l., Getty Images/Mark Moffett c., Corbis Images/Piotr Naskrecki t.r., images.de/BIOsphoto r., Focus/Science Photo Library/Philippe Psaila b.r., Getty Images/

Dorling Kindersley b.r.P. 46-47: laif/Wiggers/Hollandse Hoogte l., jovoto.com/Kenneth Lopez, Pedro Almonte r. (PR)P. 48-49: fotolia/emanuelagrigoras t., fotolia/memorialphoto m., iStock Photo (5x) Ecelop/Vecdog b., PR + claim b.r.P. 50: Focus/Science Photo Library/Dr. Juerg AleanP. 51: Corbis Images/Monty Rakusen t., PR

ComPetenCe + VISIONS

New INdustrIal revolutIoN?

Factories are becoming more flexible, more efficient and

more intelligent. Machinery are starting to interact with

products. As individualized factory products take over,

are we leaving the age of mass production behind?

CHaLLengeS + SOLUTIONS

uPdate: KdF 5MF

This multifilter maker from Hauni is a true all-rounder,

equally at home in a mass production context, making

small batches or performing experiments in a company’s

R&D department.

ExPERIENCE + reSPonSibiLity

ModularIty at Its Most basIc

Whole worlds can be created using those familiar

plastic bricks with the six studs on top. With Lego now

available for adults too, the inventive Danish manufac-

turer is riding on the crest of a wave.

signals


Euromonitor International brings you the latest market intelligence for the global

tobacco industry. Use our research to gain a greater understanding of national markets

and follow emerging trends.

Our research provides: • Detailed coverage of cigarettes, cigars, smoking tobacco, and smokeless tobacco• Market volume and value sales performance• Company shares, brand shares and distribution trends• Legislative developments, taxation and duty levels• Strategic analysis of the key factors influencing the industry

For more information on our full range of industry reports, visit us at www.euromonitor.com/tobacco

“Over the next 5 years the Russian and US cigarettes markets will decline by the equivalent of

Bangladesh’s entire annual sales”Euromonitor International

Euromonitor International brings you the latest market intelligence for the global

tobacco industry. Use our research to gain a greater understanding of national markets

and follow emerging trends.

Our research provides: • Detailed coverage of cigarettes, cigars, smoking tobacco, and smokeless tobacco• Market volume and value sales performance• Company shares, brand shares and distribution trends• Legislative developments, taxation and duty levels• Strategic analysis of the key factors influencing the industry

For more information on our full range of industry reports, visit us at www.euromonitor.com/tobacco

“Over the next 5 years the Russian and US cigarettes markets will decline by the equivalent of

Bangladesh’s entire annual sales”Euromonitor International

dw_anz_240x310_Euromonitor.indd 1 29.04.14 16:05

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