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KNOLL Maschinenbau GmbH Schwarzachstraße 20
D-88348 Bad Saulgau

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+49 (0) 7581/2008-0

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+49 (0) 7581/2008-140

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KNOLL gives customers energy-efficient systems

At AMB in Stuttgart, from September 16-20 in Hall 6, Booth C38, KNOLL will demonstrates its special expertise in the conveyor, filter, and pump product sectors. The focus of all the company's products is energy efficiency, sustainability, and space savings. The latest model of the MicroPur®, the F series, will be presented for the first time. Its ideal area of application is metal carbide and HSS tool grinding, as well as honing and lapping. Allowing you to achieve a degree of filtration of less than 3 μm, it is able to separate out incredibly small impurities from oil. Additional advantages of the new F series include the reversible flow technology, which is even more effective than before, extending the service life of the filter cartridges and reducing maintenance costs. The VLO vacuum filter is aimed at the manufacturers of gear hobbing machines. It reveals its special efficiency when grinding beneath oil. With the new design, up to three filter modules, each with a flow rate of 300 l/min, can be stacked one on top of the other. Pumps fitted with frequency controllers, along with the associated valve technology, play an important role, providing precisely the required level of filtration in order to save energy. It is often even worthwhile to retrofit existing systems. We have developed the E-PASS in order to test them with an efficiency analysis. Bridging the gap between KNOLL pumps and conveyors are what are known as shredder pumps. These centrifugal pumps are able to shred long chips, predominantly of aluminum, to pump-appropriate size and then to pump them with the cooling lubricant into the central preparation station.

 

Further information

 

KNOLL systems provide security

A long-standing cooperation connects KNOLL and a manufacturer of precision steel pipes. Several systems have already been delivered and are in use – admired based on their proven, extremely reliable system technology, availability, and system stability. Now the customer needs a system concept for supplying cooling lubricant to a pipe testing system. A special challenge was making the cooling lubricant available with the greatest purity and at high pressure. We proposed the system concept and implemented the requirements with CA 100 centrifuges and our proven KTS high-pressure pumps.

 

System technology

  • 2-stage cooling lubricant filter system via scraper conveyor with permanent sludge discharge
  • Sedimentation and automatic sludge discharge
  • Full-stream filtration via completely automatic fluid centrifuges
  • High-pressure pump: special model with quick-switch valve
  • Clean coolant pumps with protective filters installed inline and plate heat exchanger
  • Metering and mixing device for automatic refilling

 

System configuration

  • Material: steel grit
  • Working processes: pipe cleaning and pipe testing
  • Volumetric flow: approx. 170 l/min
  • Cooling lubricant: emulsion
  • Concentration: 5 - 8%
  • Operating temperature: 25°C
  • Nominal degree of filtration: < 5 μm
  • Residual dirt content: < 10 mg/l

 

KNOLL OPEN provides an opportunity to see world-class tennis

The KNOLL OPEN was held from July 28 to August 3 in Bad Saulgau. It is a world-ranked ladies tennis tournament featuring $25,000 in prize money. A total of 2500 visitors attended the tournament. The first seed, Maryna Zanevska, won the tournament in front of 600 spectators. The 20-year-old Ukrainian thus makes a small jump on the world rankings list and is aiming to qualify for the US Open. The KNOLL OPEN has established itself as a tennis highlight in Upper Swabia. And it's not for nothing that it was awarded the title of best international tournament in the German Masters Series this past November. This prize honors the effort required for the organization of a perennially successful event. The reaction to the tournament can also be determined from the number of visitors to the website: 26,742 visitors with 250,623 page calls, meaning that on average, each visitor informed himself about the tournament standings 10 times. In addition, there were 23,358 live stream calls, indicating that some spectators were also watching "live" on their computer screens.

 

 

 

With KNOLL GESUND, the outlook is brilliant

There was a lot happening at KNOLL GESUND in the spring/summer: from cooking workshops to spinning classes to kickboxing, aerobics and suspension training. A special highlight was the climbing event in July in the Naturpark Oberes Donautaul in Beuron-Hausen. Under the leadership of a qualified guide, five employees tested their courage and their limits and demonstrated teamwork and responsibility in the course of this activity. After a warmup program and a thorough safety training, the climbing program started on secured and suitable rocks. After the climb, the group was rewarded with a beautiful view from the top of the rocks. The descent was suspended but well-secured, featuring slow rappelling. There will also be numerous offerings in the fall. Some of the courses mentioned above will continue. The next KNOLL GESUND flyer will provide an overview of all courses; it will be sent out after the vacation period ends.

 

 

 

 

Aid project provides people in Burkina Faso with hope

KNOLL has supported educational projects in Burkina Faso with its "Mangos for Education" campaign since 2009. The "Hilfsfonds Burkina Faso e.V." association imports 80,000 mangoes a year and sells them in Germany via partner vendors; our company is one of these. The association collects all of the revenue, using it to provide aid in Burkina Faso. This way, a new school or vocational school is created every year. At the same time, the project assists employees on-site by paying them 20 cents per mango washed and packed. This nearly doubles their average annual salary. The revenue for Burkina Faso from the sale of mangoes at our company amounts to approximately EUR 2500. The project is organized by our trainees. They are responsible for the individual departments' orders as well as for the overall order. This year, 400 cartons of mangoes (with approximately 8 - 11 fresh mangoes per carton) were ordered, plus approximately 750 packages of dried mangoes.

 

Filter Change

A long-standing cooperation connects KNOLL and a manufacturer of clamping and gripping technology. Various KNOLL systems are already in use – admired based on their proven, extremely reliable system technology, availability and system stability. Now KNOLL has planned the entire system concept including hall piping for sophisticated multi-level filtration; it was also responsible for assisting with assembly, start-up, and production. The main components were constructed redundantly. The installation location and the associated logistics and delivery presented a special challenge.

 

System technology

  • Multi-level filtration
  • Sedimentation in the desludger and automatic sludge discharge
  • Pre-filtration with drum gap filter
  • Full-stream filtration due to automatic reversible flow filter
  • Vacuum filter for bypass cleaning and preparation of the desludging from the reversible flow filter
  • Frequency-regulated clean coolant pump for the need-based supply of the machines
  • Metering and mixing device for automatic refilling
  • Coalescence precipitator for the separation of extraneous oils
  • Plate heat exchanger with 300 kW cooling capacity for the tempering of the KSS
  • Safety catch pan (WHG)

 

System configuration

  • Material: high-alloy steels
  • Working processes: turning, drilling, cutting
  • Number of machines: 20
  • Volumetric flow: 5000 l/min
  • Cooling lubricant: emulsion
  • Concentration: 5 - 8 %
  • Operating temperature: 25°C
  • Nominal degree of filtration: 30 μm
  • Introduction of extraneous oil: medium
  • Chip shape: long, bushy
  • Chip precipitator: via machine-supplied chip conveyor

 

 

 

 

 

 

Change of perspectives

KNOLL is participating in the program "Inclusion in Upper Swabia". In the spring, KNOLL trainee Julian Bechtle worked closely with Marcus Baumgärtner for one week in the Upper Swabian Workshop for the Disabled (OWB) in Mengen. Baumgärtner then came to KNOLL for one week. The exchange was part of the "INIOS – Inclusion in Upper Swabia" program. The project "Change of perspectives" allows trainees in regional companies to spend one week in a workshop for people with disabilities (WfBM) and in return, it allows people with disabilities to work one week in regional companies. KNOLL training manager Peter Widmann believes this is a positive development: "We learned a lot. Readiness to help others, openness and acceptance of one's fellow people who are different have increased substantially." Julian Bechtle sees things similarly: "For me, the cooperation with Marcus was enriching, especially the warm interaction. Surprising was that products and quantities similar to what we produce in chipping were also produced there." Managing Director Matthias Knoll is convinced: "Interpersonal skills are important to us. The exchange offers outstanding possibilities for gaining practical experience. Starting in the coming year, we would like to expand the project to all trainees and naturally also invite other employees of the OWB to visit us." For more details about the exchange week, see: http://www.inclusive-education-in-action.org/inios-hd.html

 

What is inclusion?

 

Everybody should have the opportunity to participate completely and equally in all social processes. A milestone here was set by the UN convention on the rights of persons with disabilities, which went into force in Germany in 2009.

 

What is INIOS?

 

"INIOS - Inclusion in Upper Swabia" is a program for inclusion in work and the creation of inclusive life and working worlds where the differences between people are the rule. The project initiators are the Institut für Technik und Arbeit (ITA) and a series of other participants. The project is supported by the "Aktion Mensch."

 

Incorporated: VLO filter technology

KNOLL supplied the filter system technology for a manufacturer of transmissions and gear sets. The vacuum filter VLO 300-2 was selected. The VLO is especially well-suited for the production of gear sets and here for the the processing of abrasive fabric. In addition, these filters' compact installation space fits well in the available space. The KNOLL system was incorporated into an existing machine design and replaced the previous system. In order to guarantee a smooth transition, KNOLL integrated some components from the existing system and ensured the adaptation to the existing control design.

 

System Technology

  • Vacuum filter VLO 300-2
  • Immersion recooling unit supplied by the customer

 

System configuration

  • Material: steel, 42CrMo, 20 MnCr, manufacturing of worm gear shafts
  • Working processes: grinding, scrubbing, finishing
  • Grinding disk material: corundum
  • Number of machines: 1
  • Volumetric flow: 200 l/min
  • Cooling lubricant: oil
  • Viscosity at operating temperature: 50 mm²/s
  • Operating temperature: 2°C
  • Nominal degree of filtration: < 50 μm
  • Introduction of extraneous oil: no
  • Chip form: abrasive cloth
  • Mass flow: between 10 - 20 kg/h
  • Chip discharge: continuous

 

 

Established: Products for cooling lubricant filtration

At GrindTec in Augsburg in March, KNOLL focused on demonstrating the MicroPur® with integrated automatic slurry treatment, also for stand-alone systems. Trade visitors showed great interest in this. The warm reception made clear that KNOLL is well-established and in a good position when it comes to products for filtering cooling lubricant from grinding processes and central solutions. In an adjacent booth, another company was demonstrating its own machines integrated with the MicroPur® – a pleasing reference. Overall, it was clear that customers and potential customers greatly admire KNOLL's user-oriented solutions.

 

Further information

Press release

 

 

 

Inspired: Training Day

Approximately 450 visitors accepted the invitation to KNOLL's training day on April 5. Visitors included pupils from a wide variety of different kinds of secondary schools, as well as interested parents. The visitors were assisted first and foremost by the highly motivated KNOLL trainees. Training is greatly valued at KNOLL. The goal of this annual event is to present the training possibilities at KNOLL "live" and on-site. A brief tour with presentations of the company and its products provided an overview of the entire company. Visitors were able to learn more at various information booths about the individual professions for which training is offered, the talent pool, and personnel development at KNOLL. The offerings were rounded off with the AOK. At the AOK booth, visitors received advice on health topics and they could take a balance and coordination test on the balance board. The visitors were obviously inspired by the well-tended and bright facilities, the first-class machine park, and the many and varied offerings for trainees and employees.

 

New: the Personnel Office

Detecting trends and anchoring them at the company, transferring market conditions into solutions – KNOLL has restructured its personnel department in order to accommodate the growing number of employees. We regard this as an appropriate response to demographic change and the resulting scarcity of trained workers. KNOLL would like to be a business partner for its current and future employees.

 

Purity law? Clearly.

KNOLL advertisement 2014

We Swabians place great value on cleanliness. This is why we take the purity law very seriously. When we are drinking our beer in the evening and for our first-class filter products during the day: the MicroPur® superfine filter is a winner with its great filter fineness (1-3 μm). This is how dirty oil becomes clear.

 

More information to the finest filter MicroPur®

 

KNOLL training - still developing

Qualification is the foundation of personnel development – the current KNOLL training catalog begins with these words. The management would like to encourage employees to take advantage of the extensive offerings. There are many development opportunities for everybody.

 

KNOLL talent pool - coming right along

At KNOLL, employees with particular abilities have long been encouraged to develop these. In order to increase the number further, we have reworked the previous talent pool concept. The program is aimed at employees of all ages from all areas of the company, regardless of whether in Administration or Production. A defined selection process and a committee decide who will be included in the talent pool.

 

 

 

 

KNOLL at Trainee Marketplace - get still closer

At the beginning of February, the KNOLL trainees attended the professional information exchange "Trainee Marketplace." In January, there was a workshop at KNOLL, "Trade show training for trainees." The trade show in Bad Saulgau's vocational school center offered the KNOLL trainees the opportunity to gain some experience presenting the company. Required were first and foremost the training professions and the product portfolio. A KF filter served as a trade show exemplar. The reaction was positive and chance brought a group of English-speaking exchange students from France to the KNOLL booth. Therefore, there were also conversations about the topic of training in English.

 

KNOLL system technology - still more flexible

A well-known manufacturer of CNC machines, metal carbide and diamond tools has selected KNOLL for its system technology. For even in the early planning phase, KNOLL was able to guarantee a great deal of flexibility. A challenge for the project was the constantly increasing production capacity of this rapidly-expanding company. The modular basic concept offered the opportunity to react to capacity changes in the course of the project with custom-tailored solutions. In addition, an interim solution for a transition period was provided on loan. The system, when fully installed, currently has a filtration capacity of 980 l/min and it can be expanded to 1900 l/min. The expansion is already prepared; it can be implemented without production downtime.

 

System technology
MicroPur® 960F filter system, AK 50 automatic concentrator, DKO1000 continuous-flow cooler, FKB/14000 safety catch pan

 

System configuration

Material: metal carbide; Working processes: rough grinding, finish grinding; Machines: 9; Volumetric flow: 850 l/min; expandable to 1900 l/min; Cooling lubricant: oil; Chip form: short

 

Special features/requirements
System is prepared for additional stage of expansion; As-needed and efficient filtration with superfine switching processes and process visualization; Maintenance-friendly: filter elements can be replaced during ongoing operation; Complete recovery of valuable raw materials thanks to effective regeneration system

 

Further Information to our central systems

 

Systems engineering with distributed functions

KNOLL supplied a camshaft manufacturer with a central filtration system for its grinding operations. The material in question is through-hardened and induction hardened steel. The scope of services provided by KNOLL included the delivery and placement from the foundation up, as well as installation of the cooling lubricant supply system complete with the pipework in the cooling lubricant plant. The systems engineering comprises a modular filtration system with up to 4 vacuum filters; spacesaving cylindrical tank systems for storage and refilling of cooling lubricant; a materials handling system for the removal of grinding sludge and automatic filling of containers; a temperature control system with 300 kW refrigeration capacity, and a fluid centrifuge for bath maintenance. A briquetting press supplied by the customer for the recovery of machining oil rounds off the fully automatic cooling lubricant treatment and grinding sludge disposal system. The installed filtration stages are: a full-flow filtr tion stage via a continuous conveyor belt (20 μm), a partial-flow bypass filtration stage for spindle cooling (5 μm), and a bypass filtration stage for bath maintenance including centrifuge (3 μm). KNOLL came through with flying colours by delivering modular systems engineering without filtering agents and an integrated concept tailored to the customer's specifications. Both parties sealed their mutual trust in the form of a five-year contracting agreement . KNOLL will assume the role of plant operator over the contract term and, therefore, will be responsible for all inspections and maintenance work necessary to ensure trouble-free operation. 

 

Further information to our central systems

 

Integrating a transport system flexibly

The TSS transport system by KNOLL is now being used to good effect by a producer of high-performance polymers seeking to make its production process even more efficient. The customer was searching for a system that is flexibly adaptable to the production process and expandable on a modular basis. The TSS transport system meets all these criteria. It is used after the polymer curing process in the oven. The mould and the carrier pallet are transferred to a TSS truck at a transfer station. This truck is conveyed to a cooling zone comprising a conveyor belt with six buffer stations. Here, an enclosure with two high-speed gates ensures that the material is uniformly cooled. The heat which is released in this process is piped into the customer's heating system. Separate scissor-lift tables with a rotator unit remove the polymer mouldings so the moulds can be cleaned and prepared for the next process cycle. An additional enclosure is used for cooling the large plates.

 

Further information to the KNOLL transport system TSS

 

Pumping foodstuffs gently

A manufacturer of high-quality soups chose an MX progressing cavity pump for processing its products. The products in question are known for their fresh ingredients sourced from market halls in Munich. To ensure freshness, ingredients are processed immediately and conservatively. As a matter of principle, no additives or preservatives are used. The MX progressing cavity pump meets the customer's requirements to the full. It pumps and dispenses ingredients freshly and gently. Outstanding features of the MX pump include its enlarged suction housing with a nominal width of DN65 and its free spherical passage which allows particles up to a size of 22 mm to pass through. This allows chunks of both meat and vegetable to be pumped gently and without damage. The application involves handling a solids content of up to 25%. Other features of the pump are a max. pressure of up to 10 bar as well precision dispensing and control by means of a servo gear motor.

 

Further information to the KNOLL progressing cavity pumps MX

 

A thank-you for all your hard work and dedication

Our best wishes go to Johann Miller, Rimma Schott and Giorgio Secci, who retired. In 2013, Ralf Burkhart, Markus Michelberger, Peter Widmann, Arno Arnegger and Achim Schädler celebrate 25 years with KNOLL. We would like to take this opportunity to thank them sincerely for so many years of hard work and dedication.

 

 

RONDO relies on MX

For the opening of a new production location, the company RONDO FOOD GmbH & Co. KG ordered 16 progressing cavity pumps in the MX20 series with delivery rates between 15 and 209 l/h. This manufacturer of snack products for dogs and cats has worked with KNOLL since 2006 and, due to its own high quality requirements, it relies on the MX progressing cavity pump. Rondo Food places great value on the hygienic and high-quality processing of fresh raw materials.

 

Decisive advantages

  • 10 bar per pressure level thanks to the EvenWall® technology of the stator with its high pressing operation
  • Easy to service with quick and easy disassembly of the pumps thanks to the toolbox principle
  • Low variety of spare parts (pumps only vary in the pump assembly size)
  • Gentle product conveyance (pieces of meat in the slurry are not destroyed)

 

MX20 basic data

  • Maximum pressure: 40 bar
  • Delivery rate: 5 – 5,600 l/h
  • Viscosity: up to 200,000 mPas
  • Temperature: -30 °C to +140 °C
  • Free sphere passage: up to 22 mm
  • Operating parameters of the pumps
  • Medium: meat slurry with meat pieces
  • Viscosity: 1,000 – 3,000 mPas (consistency comparable to applesauce)
  • Solid content: 10 %
  • Particle size: 1.5 x 0.5 mm
  • Medium temperature: 5 °C
  • Delivery rate: 15 – 209 l/h
  • Pressure: 12 – 20 bar 

 

Further information to the progressing cavity pump MX

 

KNOLL relies on performance

The construction at KNOLL continues. The goal is a sound future for the production location Bad Saulgau. Impressive figures for the street and land-exchange measures alone lie behind the new construction project: the construction site is approx. 14,500 sqm large and thus larger than two official soccer fields. In total, approx. 2700 cubic meters of soil were carried away; most of this has already been used for re-cultivation. Approximately 80 to 100 truckloads were stored temporarily so that a large green space can be created after completion of the construction project. The construction site digging produced approximately 1300 truckloads full. The delivery and installation of sound gravel and pure recycled concrete material filled approximately 2000 truckloads. The new street areas created are nearly 2800 sqm large.

 

Just a click away!

NEW: KNOLL training on Facebook

KNOLL is now taking a new approach to the topic of training: since the start of February, news on training opportunities can be found on Facebook at www.facebook.com/knollausbildung. The page is an information platform complementary to the KNOLL website and is updated by trainees. In particular, KNOLL aims to reach potential trainees more quickly via Facebook. Trainer Dirk Reiner is responsible for monitoring.

 

KNOLL E-PASS

Energy Savings - Guaranteed!

 

Our PQ-Tronic control technology provides optimized energy for high-pressure pumps. Proper pump design, elimination of "overflow", and the use of speed-controlled motors can reduce costs by up to 70 %.

 

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