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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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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 health - still more intensive

The course "Swimming right" was a highlight in 2013. Every participant learned something. Currently, there are discussions with the TSV about repeating this course. The BackFit course is also a perennial hit, perfect for strengthening the back and as a preventative measure. Overall, participation in KNOLL health is accelerating: at the moment, there are six courses ongoing. And the plan includes driver safety training, a cooking course, a smoking cessation seminar, the formation of an office design project team, and operational rehabilitation management.

 

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

 

Our young talent

KNOLL currently employees 100 trainees, 36 of whom joined the company in September. With a workforce of 812, our ratio of trainees to employees is a remarkably high 12.3 %. "Part of our company philosophy is that we strongly believe in training our own new recruits. This is why KNOLL trainees are integrated into the company culture and processes from the outset", Matthias Knoll explains. Of course, that is predicated on strategic long-term planning and an intuitive feel for future needs. This year, for example, KNOLL offered, for the first time, a degree course in Industrial Engineering. This combination of technical proficiency and business administration expertise is very much in demand.

 

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.

 

Keeping fit all year round

Specially discounted fitness club membership cards and courses are available to our employees all year round as part of our KNOLLGESUND fitness programme. In addition, the year was chock full of topic-oriented promotions. The kick-off event was held in January, an ergonomics training course for office staff provided by external ergonomics consultants. This was followed by a men's and women's health week featuring lectures on nutrition. Relaxation courses and driving safety courses were held during the spring. Consultations with staff returning from sick leave began during the summer as part of a new preventive scheme aimed at promoting health. Swimming was a very popular course option during the autumn. Planning is already under way for 2014, when staff can look forward to another varied programme of activities.

 

Excellent response

The EMO in 2013 received an excellent response: in all, nearly 145,000 visitors from more than 100 countries attended the six-day trade fair in Hanover. This year, according to a press release by the event organiser, the main areas of interest were solutions for improving energy and resource efficiency, enhanced ease of use and intelligent networking of machines, in addition to the usual topics of cutting production costs and increasing flexibility in production. KNOLL also has good news to announce. The KNOLL booth offered interesting dialogue opportunities and excellent solutions. Visitors were treated to an all-round feel-good package set against an extraordinary backdrop. "The leopard-look KNOLL booth was quite an attraction. The response to our products was excellent", reported our trade fair team.

 

Originality is everything

The KNOLL booth at the EMO successfully sported an eye-catching leopard outfit. As such, it reprised the theme of another successful advertising campaign earlier in the year: the VLO vacuum filter in leopard look was "Advertisement of the Month" of April 2013 in Industrieanzeiger magazine. According to an analysis by advertising scientist Dr. Zschocke, the advertisement appeals, in particular, to industry professionals by virtue of its unusual style of presentation. Its originality lies in the association it creates. The leopard is a hunter and the VLO vacuum filter hunts particles in grinding oil.

 

Further Information to the vacuum filter VLO

 

The environment is ultimately the winner

For the second time in succession, KNOLL has been nominated for "Advertisement of the Year" by Konradin-Verlag. The award was presented at the KNOLL exhibition booth during the EMO mechanical engineering fair in Hanover 2013. The core theme of the advertisement was that of sustainability. The underlying idea is to promote energy efficiency and resource conservation in all KNOLL product segments, and within the company itself. The grass-covered pump advertisement awarded first prize by the jury appeared in Industrieanzeiger magazine. Dr. Jochen Zschocke of the IFUMA Institute for Market Research in Köln gave the following scientific assessment of the award-winning advertisement: "The grassy green pump is very much in keeping with pop art in that it takes an everyday product and artistically alienates it while representing it in a photorealistic way...The headline "energy efficient" also conveys the message that pumps by KNOLL save energy while curbing CO2 emissions and reducing lifecycle costs."

 

 

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.

 

Trainees rely on KNOLL

36 new trainees are starting at KNOLL. The trainee quota is thus increasing to more than 12.3 % - of 812 employees, the company now employs 100 trainees. Of the new trainees, a total of 3 selected a Baden-Wuerttemberg Cooperative State University course of study, 3 selected technical product design, one trainee will become an information technology specialist, there is one machine and systems operator, there are 4 commercial trainees (of these 2 have additional qualifications), two mechatronics specialists, 6 electronics specialists, 14 industrial mechanics, and 2 warehouse specialists.

 

Continue reading

More Information about training at KNOLL

 

KNOLL health relies on swimming

Swimming is an ideal, joint-sparing endurance sport. KNOLL health's current offerings serve to provide preventative measures against illnesses of the muscular-skeletal system and heart and circulation problems. The reception of the current offerings has been overwhelming. A slow-burner is the topic of ergonomics. An ergonomics training for all production employees is currently being planned. And here's another pleasing number: this year, KNOLL employees have already participated 800 times in KNOLL health actions.

 

Jani relies on a win at the KNOLL Open

The world-ranked KNOLL OPEN ladies' tennis tournament celebrated a special anniversary this year: the eponym and main sponsor KNOLL Maschinenbau organized this tennis event for the 10th time. Meanwhile, the tournament offers prizes of $25,000. This year, the Hungarian Réka-Luca Jani took the prize money home. The organization and location distinguish themselves through their professional handwriting. This also pleases Fed-Cup chief Barbara Rittner, who assisted and supported the players of the Porsche up-and-coming team during the tournament week.

 

 

 

KNOLL opened the plant gates for an exceptional meeting of superlatives: the KNOLL Days offered unique insights into the company. A total of 700 visitors took us up on our invitation. Before the tour, there was a press meeting. Regional newspapers and trade publications from Germany and Switzerland were especially interested in KNOLL's recipe for success. According to Matthias and Jürgen Knoll, "You need courage to make decisions." Guests from all over Europe traveled to attend this in-house trade fair that catered to a professional audience. The tenor of the meeting was customer relationship management writ large. The KNOLL Days distinguished themselves by providing every visitor with a personal advisor, who accompanied him or her and was available to answer questions.

 

 

 

The employees' day was scheduled right after the KNOLL Days. Here, KNOLL employees proudly displayed "their company" to their families. In addition to company tours, horse and carriage rides through the neighboring Mühlental and many other attractions, a highlight was a visit by Paul Breitner, who in an interview made some interesting comparisons between careers and soccer games.

 

Performance wins

"KNOLL Gesund" (the company's health-promotion program) is bearing fruit and producing successes. As part of the KNOLL Gesund program, the sales employee Paul Merk (2nd from left) wanted to refine his Nordic walking technique last year and test his performance by participating in this year's world championship. The result is breath-taking: at the Nordic walking world championship in the Bavarian forest in Roding, Paul Merk took ninth place in his age group. With the team he became a world champion. Our warmest congratulations to him!

 

New blood wins

For the sixth time, KNOLL organized a training day for vocationally-oriented pupils from local secondary schools and their parents. More than 300 people attended this event, which was held in April. There was particular interest in the mechanical and commercial professional tracks. Product design is also an area in which there is lively interest. The registration deadline for training in the coming year is December 2013; early registration is entirely worthwhile.

 

 

 

Luck wins

Until August 2013, the TSS prize competition gave the chance to win an iPad every month. Among the winners are Markus Widmann of Franz Kessler GmbH in Bad Buchau (April), Walter Naffin of MTU Friedrichshafen GmbH (June), Pierre Stuppy, Märkisches Werk GmbH in Halver (August). Congratulations!

 

What is good for you?

KNOLL Gesund

 

In February, as part of "Healthy KNOLL"" there were health weeks for women and men. This allowed KNOLL employees to familiarize themselves with a broad selection of health offerings. The success proved the concept right: with more than 175 registrations, more than 20 % of KNOLL employees participated. Courses will now be offered based on the best-attended courses during the "try-it-out hours". At the moment, it looks like courses will include yoga, Feldenkrais, and spinning.

What was the point of the "health weeks"? 

Jana Masur, Personnel Department, explains: "The 'health weeks' consisted of 'try-it-out-hours' relating to exercise, relaxation, and nutrition, and they were organized for the first time in this form. Our goal was to provide 'try-it-out hours' so that employees could try out new offerings without having to register for courses right away. This way, the Personnel Department learned which offerings interest the employees so that we can offer appropriate courses."

 

The new dispatch centre of KNOLL
The new dispatch centre of KNOLL

Future viability

Functional, minimalist and aesthetic. This is the impression gained when viewing the skeleton structures of our dispatch centre and loading zone. The aim is to achieve the highest levels of performance and efficiency. In addition to four gantry cranes each capable of carrying 2.5 tons, there are four column slewing cranes each with a load capacity of 1 ton. The building is heated by dark radiators while the office and social buildings are heated with groundwater by a heat pump. The domestic water is heated by a solar system. Under the 8.5 m high building canopy covering an area of 2,100 m² there are two loading cranes each with a load capacity of 10 tons.

 

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 %.

 

More information

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