KIC Krones introduces smart hygiene concept at Starzinger

Victor Starzinger and his mother Ludmilla represent the company’s fifth and fourth generations of leadership. Victor describes the company’s philosophy as follows: “We are an innovative, modern, and motivated family enterprise. Market demands change fast – and we have to keep up. We serve over 1,000 co-packing clients and filled more than 1,200 different SKUs in 2020. To meet this demand, we need a strong partner to consult with on both technology and cleaning matters.”

To meet the market’s demands, we need a strong partner to consult with on both technology and cleaning matters. Victor StarzingerManaging Director of Starzinger

Production manager Johannes Hauser adds: “What distinguishes us from the competition is that we are continuously adding the latest trending products to our portfolio – and have done so for years – like cold brew coffee, BCAA drinks (drinks containing branched-chain amino acids), and, now, hard seltzer. But we really run too few sensitive beverages to warrant installing a true aseptic line. After all, these trends come and go very quickly.” Hauser goes on to say, “And because we’d be investing not only in an aseptic line but also in its maintenance and operation, we decided instead to put our money on solutions that enable us to meet the highest possible standards of hygiene on our conventional lines.”

And so, Starzinger opted to introduce a hygiene concept that meets those high standards and can apply equally to all of its lines.

“The higher the demands on us, the stronger we need our partner to be”

As when Starzinger chose Krones to deliver lines and equipment, the decision to bring KIC Krones on board for the hygiene concept arose in part from the companies’ many years of successful collaboration. Initially, KIC Krones was “just” the adhesives supplier. Then, in 2019, detergents were added into the mix. And that’s how the two companies came to discuss the possibility of overhauling the entire hygiene concept for the lines.

We realized that the people at KIC Krones really know what they are doing: They have a genuine interest in taking us in the right direction. Johannes HauserProduction manager at Starzinger

At Starzinger’s request, Simone Weiherer, a member of KIC Krones' field staff, ran a check on the function and efficiency of all the machinery, drew up an overview of the current state of things, and then used this information to develop an integrated concept. That was an excellent opportunity for KIC Krones to demonstrate its competence as a system partner. “The higher the demands on us, the stronger we need our partner to be. So it’s important that our cleaning concept be well aligned with our machinery. We’ve been working with Krones for many years now, and nearly all of our filling systems are from Krones,” explains Johannes Hauser. “We then realized that KIC Krones really know what they are doing: They don’t just want to sell us something. They have a genuine interest in supporting us for the long term and taking us in the right direction.” 

In 2019 and 2020, KIC Krones optimized the cleaning technology on one PET line and one glass line (excluding the pasteurizer) in Starzinger’s Deutschkreutz plant on Austria’s border with Hungary. After that, it was time to tackle the hygiene concept for the main plant in Frankenmarkt.

“Not a single complaint”

The integrated concept is easily explained: Clean as much as necessary without using more cleaning agents than necessary. And be as gentle on the machines as possible. Because, of course, the diverse range of products makes for more frequent product changeovers – and cleanings.

“A shorter, more effective CIP process makes for shorter downtimes and lower costs,” stresses Johannes Hauser. Nadine Prehofer, head of quality assurance at Starzinger, adds: “The microbiological situation is vastly improved since we’ve been working with KIC Krones. We’ve been able to reduce our costs for cleaning agents while at the same time continually improving product quality. Last year, we didn’t have a single complaint from customers with respect to microbiological safety.”

In the summer of 2021, a canning line and a PET line as well as the portion of the glass line up to the bottle washer had been transitioned to the new hygiene concept. For the two remaining canning lines, Starzinger has ordered  chlorine dioxide systems from KIC Krones that will go into operation in early 2022.

Krones and KIC Krones offer synergies for an ideal solution

“For us, it’s very important to monitor outcomes and continually ask ourselves what we could do better,” says Nadine Prehofer. “A continuous improvement process is also a requirement for IFS certification [from the International Food Safety and Quality Network]. At the same time, it’s crucial to us that a third party continually review our processes to ensure that no errors slip in that could, in a worst-case scenario, jeopardize product quality. KIC Krones actively supports us in this respect and proposes solutions.”

Johannes Hauser adds with a wink: “And every once in a while KIC Krones can learn something from us since we’re often among the very first to put out a new product that even Krones hasn’t seen yet.”

We appreciate the synergies that arise from the collaboration between Krones and KIC Krones. Johannes HauserProduction manager at Starzinger

To sum up, Johannes Hauser views the new hygiene concept as the ideal solution: “It was, hands down, the right way to go. We can never stop improving – our customers expect it of us and we expect it of ourselves. Without a doubt, this transition has put us on the right track,” says Hauser. “We also appreciate the synergies that arise from the collaboration between Krones and KIC Krones. Because who knows the machines better than their manufacturer? It’s really the only way to strike the ideal balance – achieving lasting, gentle, and frequent cleaning while saving resources and reducing costs.”