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Branches
Automatic storage and retrieval systems
Construction
Food and Beverage
Paper
Tobacco
Give the space the dimensions of your requirements!

Working closely with customers, KÖHL develops flexible, cost-effective warehouse solutions. Whether fully-automated high-stack stores or racking systems for buffer-, inventory of distribution purposes - efficiency and transparency is always writ large at KÖHL. KÖHL offers fully-automated solutions adapted to special customer requirements.

KÖHL systems are combined with components from leading partners. The result: full warehouse systems with fully-automated storage and retrieval of pallets, containers, cardboard boxes or rolls that set a newbenchmark in terms of standards.

    Branches
    Construction
    Food and Beverage
    Paper
    Tobacco
    Automation from A to Z
    Food and Beverage
    Paper
    Tobacco
    Construction

    KÖHL automation processes feature modern control systems, professional visualisation systems and intelligent warehouse management. Robotic systems for palletising, de-palletising, transporting and picking complete the range on offer. Identification and labelling processes such as barcode technology or RFID, track&trace systems for transparent planning and production processes.

        Branches
        Food and Beverage
        Paper
        Tobacco
        Construction
        Bale Divider
        Food and Beverage
        Tobacco
        Smallest Portion of a Blend

        The smallest portion of a blend is half a bale therefore HEINEN KÖHL developed the bale divider. The industrial robot picks the full C48 cases and empties them gently onto an accumulating conveyor after unwrapping and opening. While the empty C48 cases are folded and stacked by the folding device, the tobacco bale is moved to the divider.

        The HEINEN KÖHL bale divider fully automatically centres the bale and cuts it vertically in two equal half bales. Each half is then pushed smoothly onto an own stainless steel pallet, equipped with transponder. This makes an automated storage in a high rack silo and a full track & trace functionality possible for further blending.

            Branches
            Food and Beverage
            Tobacco
            Bin and Case Filling
            Renewable Energy
            Fulfilment Right To The Edge

            The filling station is available for bin filling or C48 case filling for continuous tobacco flow. The filling procedure for bins and cases will be affected automatically and optionally includes after filling fine dosing.Cases will be erected manually and can be equipped with PE-liners automatically.

            After the filling procedure liners and cases can be closed automatically before strapping. Compared to other standard filling stations the HEINEN KÖHL filling stations have a reduced height due to the use of push chains.Depending on the mass flow the filling system is available as mono, double or triple shaft filling station.

                Branches
                Renewable Energy
                Bin Handling
                Construction
                Food and Beverage
                Paper
                Tobacco
                Flexible bin handling solutions

                HEINEN KÖHL offers various flexible bin handling systems which contain different components and thus can be properly adapted to the building’s restrictions and to the process’ requirements.Besides standard solutions for the logistics of bins, the bins can be handled via distribution cart, pile handling system or automated guided vehicle (AGV).

                The stacking device of the bins is designed for fast stacking and de-stacking. Each stacking device can be equipped with a lid handling system which will automatically take off or close the lid of the stacked bins.To reduce dust emission and product degradation bin tipping will be supported by slow back moving of bins enabling product pouring.

                The tobacco will be stored in standard wooden bins which are normally equipped with an RFID chip that allows flawless tracking and control by the KÖHL WMS (warehouse management system). Even dedicated bins can be managed with our bin handling system.

                      Branches
                      Construction
                      Food and Beverage
                      Paper
                      Tobacco
                      Biogas systems
                      Renewable Energy
                      Intelligent control for safe, easy handling

                      Our innovative modular operating centre for operating biogas systems efficient is designed to save space and is highly adaptable to the widest possible range of biogas system designs. The standard 40' container houses all main functions: flexible, redundant substrate distribution, integrated heat distribution, biogas desulphurisation, digital system design, water supply, SPS control and low-maintenance compressed air systems.

                      All system components are controlled and displayed on a fully automated basis, but assemblies can also be operated manually. The display structure is intuitive in use. This gives biogas system operators an innovative technology which makes using biogas systems safe, efficient and intelligent.

                        Branches
                        Renewable Energy
                        Blending and Storing
                        Food and Beverage
                        Tobacco
                        Great Variety Of Customized Silo Types

                        A wide range of silos for storing and blending are tailored according to customer requirements. Wherever possible the silos are equipped with a minimum of high support legs by default. This is to use the floor space to maximum capacity and to have clearance below silos for free walkway.

                        Silos with wide apron are chain guided with trapezoidal cross stretchers covered by thin belt of polyethylene coated polyester fabric. Sidewalls with large windows are made of stainless steel sheet and melamine coated wooden panels may be used for cut filler.

                        Different filling modes such as multi batch mode or follow up mode can be realized to fit the needs of the production.

                            Branches
                            Food and Beverage
                            Tobacco
                            Bundle Perforation Unit
                            Construction
                            Foundry
                            Ceramics
                            Food and Beverage
                            Steel

                            For all common bundle packaging machines.

                            The Bundle Perforation Unit has been developed to perforate the foil of overwrapped bundles with lines of holes. Through easy snapping of the overwrapped foil customers are offered a comfortable bundle opening experience.

                            Expensive tear tapes will not be needed for unwrapping the bundle due to perforation by the BPU.

                            The BPU is designed to be installed in almost all common bundle packaging machines.

                                Branches
                                Construction
                                Foundry
                                Ceramics
                                Food and Beverage
                                Steel
                                Case Unpacking Robot
                                Tobacco
                                Smooth Operator for C48 cases

                                The HEINEN KÖHL case remover consists of an industrial robot equipped with a specially designed gripper, folding & stacking device and conveyors. The patented gripper is of multi-purpose type and combines case clamping, flap covering and turning of the C48 cases. Also telescope type of cartons can be handled.The robot empties the cases gently onto a flat belt conveyor and then transfers them to the folding & stacking device that automatically flattens and stacks the empty C48 cases on a pallet.As an option, the pallet can be fed automatically out of a pallet magazine and also be wrapped after loading– right ready for transport.The combination of the robot and gripper is also able to pick cases stacked in triple stacked height which enables our customers to further optimize their primary logistics process.HEINEN KÖHL has developed the case remover ensuring high operational reliability and flexibility for opening C48 cases with all types of tobacco.

                                  Branches
                                  Tobacco
                                  Casing Cylinder
                                  Tobacco
                                  The casing cylinder is equipped with a special pin arrangement to avoid the “roping effect”. The cylinder body and all elements that come into contact with tobacco are made of stainless steel. The additive is sprayed with steam via one two-medium nozzle onto the tobacco. The vapour is extracted via a continuously cleaning rotary sifting cylinder. For flushing purposes water inlet pipes are installed in the discharge hood, in the cylinder infeed and to the casing pipe network.
                                      Branches
                                      Tobacco
                                      Control systems and software
                                      Construction
                                      Foundry
                                      Ceramics
                                      Food and Beverage
                                      Steel
                                      Programming productivity and managing for success

                                      User-friendly ergonomic control

                                      Our automated systems are outstanding for being so user-friendly. Robot management is integrated as part of system management, so all system components and robots can be parametered and controlled. Modifying and optimising programmes takes just a few parameters input, specialist robot knowhow is mostly unnecessary.

                                      Software design and programming

                                      From simulation tools to SPS through to intelligent robot networking and man-machine interaction, our software solutions are tailored to your automation solution. Software tools offer full functionality, for setup, programming, position control, program process functions, diagnostics etc.

                                      With their open architecture, the control systems used can be customised to suit any plant and meet any demands. Robot software is programmed individually to suit the tasks involved. We produce an appropriate, specific parameter set for each product format; clients can then define their own parameter sets and save them independently of other software. Many upgrade options are also available which you can use to make changes/upgrades easily.

                                        Branches
                                        Construction
                                        Foundry
                                        Ceramics
                                        Food and Beverage
                                        Steel
                                        Conveyor- and transport systems
                                        Construction
                                        Food and Beverage
                                        Paper
                                        Tobacco
                                        Intelligently networked and solid

                                        Conveyor technology from KÖHL is characterised by its extremely robust supporting structure, great ease of assembly, and energy-efficient, frequency-regulated drive technology. The relevant material and transport systems are developed and manufactured in-house - according to requirements, and custom made for high material flow availability.

                                        Future potentials are sounded out with process analyses, simulation studies and calculations of economic efficiency.

                                          Branches
                                          Construction
                                          Food and Beverage
                                          Paper
                                          Tobacco
                                          Direct Conditioning Cylinder (DCC)
                                          Food and Beverage
                                          Tobacco
                                          Loosening and Enriching of Tobacco

                                          The HEINEN KÖHL DCC is designed for providing the best achievement in direct conditioning and opening of any type of lamina leaves and strips.Before the start of the process a heat exchanger is used to pre-heat the drum. Free steam is directed into the duct in order to regulate the tobacco temperature while the process is running, and this quickly influences the climate in the drum.

                                          Inserted lamina slices will be gently loosened and opened by paddles and pins within the rotating cylinder. The lamina becomes most pliable that is achieved in a concurrent of hot and oversaturated air, which surround the lamina slices from all sides ensuring an even and rapid absorption of moisture.

                                          The next processing step within the cylinder is the additional moistening of the conditioned tobacco. A dual nozzle applies water and steam into the tube of turning tobacco to raise the moisture content to the favoured level.The internal of the cylinder is designed with rounded edges allowing effective cleaning after the process.A fittings cabinet with sliding front doors is positioned next to the drum. Separating panels are used to divide it into areas for supplying the DCC with steam, water and compressed air.

                                              Branches
                                              Food and Beverage
                                              Tobacco
                                              Direct Conditioning Cylinder Casing (DCC-C)
                                              Food and Beverage
                                              Tobacco

                                              Additionally our basic DCC can be extended for a complete process of conditioning and casing tobacco. The HEINEN KÖHL DCC-C is equipped with a complete application for spraying casing on tobacco, with a dual nozzle for casing and steam in the outlet hood. The metering systems for casing and steam are integrated in the extended fittings cabinet. The supply lines for sauce and steam are thermally insulated.

                                                  Branches
                                                  Food and Beverage
                                                  Tobacco
                                                  Eco.On Energiemanagement

                                                  Sparing use of resources with a simultaneously increasing need for energy and rising energy costs call for a professional energy management system. Eco.On makes possible meaningful analyses and evaluations by which considerable potential for savings can be realised. Furthermore, successful energy management is to be understood as a continuous process of optimisation in the company. It includes integrated energy planning with the resulting improvement measures for increasing energy efficiency. In addition, the introduction of an energy management system is becoming more and more important due to statutory regulations.

                                                  Eco.On is your sustainable and integrated energy management system, which fulfils the requirements of the DIN ISO 50001 standard. It makes company energy needs and consumption transparent and supports processes and procedures to achieve set targets.

                                                  Eco.On makes it possible for you to record and analyse the use of energy and energy consumption, as well as determining the variables which affect this for all media, such as electricity, gas, water, heat or compressed air.

                                                      Branches
                                                      Embedded Automation Computer
                                                      Aircraft
                                                      Dataflow under control

                                                      Today, large volumes of data are increasingly overloading higher level IT systems. KÖHL's Embedded Automation Computer (EAC) offers the secure solution. EAC adapts interfaces, gathers process data, prepares it and provides it to the IT system in a database. If the connection is lost, the data coupler buffers the data and restores it automatically once the connection is made again.

                                                          Branches
                                                          Aircraft
                                                          End of Line Palletizing
                                                          Construction
                                                          Foundry
                                                          Ceramics
                                                          Food and Beverage
                                                          Steel
                                                          The Flexible Pick And Place System

                                                          With the special experiences and know-how, HEINEN KÖHL has developed automated systems for the tobacco industry such as end of line palletizing solution.

                                                          The end of line palletizing solution (EOL) of HEINEN KÖHL is a complex, flexible and reliable installation for fully automated palletizing of shipping cases performed by industrial robots. Such system consists of elements like case handling, robot cell, pallet supply, wrapping, labelling, safety equipment, control system, etc.

                                                          The heart of the EOL – the robot cell – picks up the arriving shipping cases from the accumulating conveyor and places them in layers on pallets. Up to four different brands can be handled simultaneously by one robot. The shipping cases can be palletized in 3 or 4 layers with changing pattern to ensure a stable pile by overlapping.

                                                          The robot is equipped with a special gripper using both, vacuum and mechanical clamping to ensure a safe conveying of the shipping case. That also increases the precision of the case placement on the pallet.

                                                          The shuttle cart or pallet conveyors bring the full pallets to an automatic wrapper and label applicator, where after the wrapped and labelled pallets leave EOL towards stock or commissioning area.

                                                          A special attention is given to the safety of the system which guarantees that no unintended accident can happen during the operation of the robot.

                                                          Several robot cells can be controlled from one master system. Along with the visualisation software HEINEN KÖHL also provides all necessary interfaces to the factory production database, ERP or T&T system.

                                                              Branches
                                                              Construction
                                                              Foundry
                                                              Ceramics
                                                              Food and Beverage
                                                              Steel
                                                              Flavour Application System (FAS)
                                                              Construction
                                                              Food and Beverage
                                                              Paper
                                                              Tobacco

                                                              For online flavouring our customers needed a system that is precise and reliable. Therefore HEINEN KÖHL developed an online flavouring system which is leading the market.

                                                              Flavouring with Passion

                                                              The Flavour Application System -FAS- is the first special unit for single and twin-track filter and cigarette makers. Its high precision pump ensures a homogeneous application of liquid flavours as well as pure menthol – being a fine tool for sophisticated flavour applications. The mobile unit allows utmost flexibility at the production facility and its modular design is easily adaptable to meet our customers requirements. The FAS in its concept is set-up to be linked to all types of filter makers and cigarette makers.

                                                              Heating System

                                                              The heating system of the FAS unit can process flavour types (e.g. menthol), that require heating in order to reach a processable viscosity. It guarantees that all vital components of the unit maintain uniform temperature during production, thus ensuring that the viscosity of the flavour remains constant from tank up to spray nozzle. The heating devices can easily be deactivated for flavour types that have a processable viscosity level at room temperature.

                                                              Tank System

                                                              The FAS unit is equipped with an external mobile tank with a capacity of about 45 litres. It can be filled and hermetically closed at separate area. The insulated enclosed tank contains a heating system permitting to melt pure menthol offline or during production. The tank is equipped with a quick-plug connection for liquid as well as for electrical supply. Changing the tank can be done without stopping the maker.

                                                              Features
                                                              • European Patent EP 2.016.840
                                                              • For Single-Track and/or Twin Track Makers
                                                              • Closed Loop Control System
                                                              • Modular Design
                                                              • No Calibrations necessary
                                                              • ATEX -TÜV Certificate
                                                              • Heating System
                                                              • Big Storage Tank
                                                              • High Precision Dosing System
                                                              • Easy and Efficient Cleaning at Flavour Exchange
                                                                Branches
                                                                Construction
                                                                Food and Beverage
                                                                Paper
                                                                Tobacco
                                                                Flavouring Cylinder
                                                                Food and Beverage
                                                                Tobacco
                                                                Get the full taste for top product quality

                                                                The flavouring cylinder is equipped with a special pin arrangement to provide a uniform tobacco flow and mixing of the tobacco. The cylinder body and all elements that come into contact with tobacco are made of stainless steel. A two substance nozzle (compressed air – flavour) is installed at the infeed plate to spray the flavour onto the tobacco

                                                                A combined unit with pump and tank, including level measuring and flavour pump is located close to the flavour cylinder on a separate frame with integrated control cabinet. The cylinder and the discharge hood are completely insulated against external heat losses.

                                                                    Branches
                                                                    Food and Beverage
                                                                    Tobacco
                                                                    Fluidized Bed Dryer (FBD)
                                                                    Food and Beverage
                                                                    Tobacco

                                                                    This drying principle is based on up-streaming hot air that flows through the holes of a vibratory conveyor and lets the tobacco hover as a homogeneous fluidized carpet inside the hood. The tobacco looses its moisture to the air and is transported toward the outlet by the vibratory conveyor.

                                                                    The hot air is generated by two energy units - one for each drying section - which can be connected to the dryer in a close or in an open loop. In the close loop only 20% of the exhaust loaded with water leaves the system while 80% of the air and consequently energy stay inside the system

                                                                    A vibratory conveyor transports the tobacco in an even layer through two drying zones. In the energy units the process air is cleaned from dust particles and is heated to the requested drying temperature. In addition it guarantees a continuous fresh air supply and a permanent exhaust discharge for perfect water load in the process air.

                                                                        Branches
                                                                        Food and Beverage
                                                                        Tobacco
                                                                        Gas Heated Drying Cylinder
                                                                        Food and Beverage
                                                                        Tobacco
                                                                        Efficient and gentle drying processes

                                                                        This very day HEINEN KÖHL offers efficient equipment, which is particularly suited to the treatment of dark tobaccos and Roll Your Own/Make Your Own.

                                                                        The cylinders display following features:
                                                                        • a wide capacity range high evaporative power at optimal energy consumption
                                                                        • high throughput rate at constant final moisture content
                                                                        • wide control range of the drying process temperature
                                                                        • no negative tobacco taste impact
                                                                        can be designed for two operating modes:
                                                                        • drying – combined heating of the wall and the process air, harmonised together
                                                                        • toasting – direct heating of the cylinder wall
                                                                              Branches
                                                                              Food and Beverage
                                                                              Tobacco
                                                                              Gravity Feeder (GF3/GF6)
                                                                              Renewable Energy
                                                                              Pure Feeding Without Tobacco Degradation

                                                                              The core of the complex feeding solutions are the Feeders. The functional principle of the HEINEN KÖHL Gravity Feeders GF3 and GF6 uses metering tube, metering belt and the dosing doffer as main components. This design guaranties a very gentle handling of cut tobacco and a non-measurable degradation as well as a permanent dosage of the tobacco amount in relation to the maker's needs.

                                                                              The complete system is subordinated to the maker. The feeder automatically sends the needed dose of tobacco by continuous motion of the tobacco flow. The air intake supports the tobacco flow and keeps it in movement for the pneumatic conveyance.

                                                                              The GF3 and GF6 feeders are well suited for feeding of 1 to 6 cigarette makers.

                                                                                  Branches
                                                                                  Renewable Energy
                                                                                  Image processing
                                                                                  Construction
                                                                                  Food and Beverage
                                                                                  Paper
                                                                                  Tobacco

                                                                                  KÖHL integrates image processing systems in your automation projects, with tasks ranging from simple testing through to complex optical measurements.

                                                                                  Features
                                                                                  • Inspection
                                                                                  • Position recognition
                                                                                  • Robot management
                                                                                  • OCD
                                                                                  • Quality control
                                                                                        Branches
                                                                                        Construction
                                                                                        Food and Beverage
                                                                                        Paper
                                                                                        Tobacco
                                                                                        IntralogistIQ
                                                                                        Construction
                                                                                        Food and Beverage
                                                                                        Paper
                                                                                        Tobacco
                                                                                        From the specialists for system integration

                                                                                        Designing cost-effective material and information flows optimised for systems requires highly-efficient logistics concepts. With its high degree of experience in customer-specific applications and specialist knowledge of automation technology, storage and conveyor systems, KÖHL are specialists in intelligent intralogistics. Acting as a general contractor, KÖHL develops, plans and implements fully-automated high-stack stores and material flow systems: from the drawing board to turnkey handover of the whole assembly. In the area of production and distribution, robotic systems for packaging and palletising solutions, internal transport and automated storage systems, full automation via PLC, material flow- and warehouse management systems generate enormous rationalisation potential.

                                                                                        Service range
                                                                                        • Automated high-stack storage systems
                                                                                        • Conveyor systems
                                                                                        • Picking- and distribution systems
                                                                                        • Robotic handling + palletisation
                                                                                        • Warehouse management and material flow systems
                                                                                        • Programmable Logic Controllers (PLC)
                                                                                        • Visualisation systems (SCADA)
                                                                                          Branches
                                                                                          Construction
                                                                                          Food and Beverage
                                                                                          Paper
                                                                                          Tobacco
                                                                                          Leer-Paletten-Kontrollsystem (LPK)
                                                                                          Construction
                                                                                          Food and Beverage
                                                                                          Paper
                                                                                          Tobacco

                                                                                          KÖHL offers a fully-automated checking system which surpasses current market requirements. This system checks Euro- and half pallets for their load bearing capacityand high shelf stackability.

                                                                                          Individually configurable and customisable sorting criteria allow for the correct assessment and sorting of the pallets according to their intended use. The system can check up to 365 Euro pallets or 450 half pallets perline per hour, depending on the module configuration.It consists of one conveyor unit for restacking the empty pallet stack, one checking line, and a subsequent sorting unit.

                                                                                          The empty pallet stack is transported by way of highly reliable and robust conveyor technology. In the pallet destacker, the stacks are separated and the pallets are fed onto the checking line. Depending on the requirements, several checking lines can be installed in parallel. The system ensures that only fault-free pallets will be fed into the material flow (palletising and conveying systems, high-stack stores and shelf operating units).

                                                                                            Branches
                                                                                            Construction
                                                                                            Food and Beverage
                                                                                            Paper
                                                                                            Tobacco
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