igus® as module supplier for KHS labelling machines


  • What was needed: Uninterrupted flow in the bottling process.
  • Requirements: No external lubricants, high wear resistance, corrosion-free and maintenance-free
  • Industry: Beverages sector
  • Success for the customer: Ready-to-install modules to ensure high precision in the work processes at very high speed.

Go to KHS GmbH The performance of a typical KHS beverage filling and packaging line: 60,000 bottles per hour, 1,000 bottles per minute and almost 17 in every second This company, which is headquartered in Dortmund, is one of the market leaders worldwide developing, designing and building such systems. KHS has a headcount of around 5,000, generated sales of around €1.18 billion in 2016 and is a wholly-owned subsidiary of the Salzgitter Group.

KHS labelling machine


The wrap-around labels must be unwound from a roll, cut to the correct length in the cutting unit and glued using a roller. Then they are applied to the bottle. The bottle rotates during delivery of the label, which is directly brushed down. This process takes place at high speed. The Innoket Neo RF labels more than 300 bottles within 20 seconds. This places high demands on all movable components, in particular on their precision. For this reason it is important that the individual components are highly wear-resistant and comply with hygiene regulations. During filling, the environment is wet or at least humid, i.e. the components must be very resistant to corrosion and common cleaning media.
Many users move disposable and reusable bottles along one and the same line and therefore require two different label types on one machine. The changeover time is therefore an important criterion, as is a fast format change depending on bottle and label sizes. Even when labelling 60,000 bottles per hour, one bottle must look exactly like the other.


This requirement profile matches the bearing technology of igus GmbH, which has already been used in various KHS systems for around twenty years. What is new, however, is that igus not only supplies the bearings, but also completely ready-to-install functional components. It simplifies the assembly and ensures high-precision, high-speed working sequences. In addition, lubrication-free components help prevent contamination - especially when empty, open bottles have to be labelled. Until now, the height adjustment of the cutting mark sensor has always been assembled from numerous parts. The complete solution is now available from igus: with linear adjustment option, clamping, measuring scale and fastening for the installation. In operation here is the drylin W linear guide WS-10-40. The company igus also provides the sensor adjustment for the cutting mark detection of the label as a ready-to-install module. A drylin W linear guide is used as the basis. The horizontal adjustment unit of the entire work table is a further complete system. It helps to adjust the distance of the roll-fed station to the basic machine. The adjustment is performed by a handle using a lead screw. The rear guidance was designed with drylin W linear guides of the type WSQ-16.
The igus components help to meet these requirements economically and with high reproducibility. The latter is always a decisive factor for beverage manufacturers with full flexibility, in order to ensure uninterrupted operation of the machine.

More pictures of the application example