KHS partners with Carlsberg to build modern brewery in China

CHINA – Dortmund-based systems supplier KHS Group has joined forces with Carlsberg Asia to establish one of the largest and most advanced breweries in Foshan, South China.

This greenfield project represents a significant milestone in the longstanding partnership between the two companies. 

KHS and Carlsberg have worked closely on numerous projects over the past decade, particularly in China.

In 2021, KHS successfully delivered two high-capacity canning lines in Dali (Yunnan Province) and Yibin (Sichuan Province), each capable of handling up to 90,000 containers per hour, even under the challenging conditions of the COVID-19 pandemic.

“On acceptance, we achieved line efficiencies of 99% and 100%—well ahead of schedule,” said Norman Gras, KHS’s global key account manager. 

Paul Kime, Carlsberg Asia’s senior director for assets, projects, and utilities, attributed their success to a trust-driven relationship.

“Our teams work as one, with a shared goal rather than a customer-supplier dynamic. This has enabled us to streamline processes and achieve exceptional outcomes,” he remarked. 

The new Foshan brewery, Carlsberg’s 27th in China, spans 16 hectares with a planned output of 14 million hectoliters.

Phase one of the project, completed with an investment of €191 million (US$200.49m), includes facilities covering 80,000 square meters.

Designed with sustainability at its core, the brewery aligns with Carlsberg’s Together Towards Net Zero plan, which targets zero emissions across its value chain by 2040. 

The Foshan brewery incorporates several cutting-edge features to ensure sustainability and efficiency.

The Sponge Brewery Concept is a standout innovation that includes rainwater harvesting and treatment systems.

This approach conserves water resources while minimizing wastewater, aligning with Carlsberg’s commitment to sustainable operations. 

The brewery’s construction prioritizes environmental sustainability by utilizing recyclable and energy-efficient materials.

These materials meet China’s stringent 3-star ecological construction standards, emphasizing the brewery’s dedication to green building practices. 

Renewable energy plays a pivotal role in the brewery’s operations. A rooftop photovoltaic system supplies up to 30% of the facility’s electricity needs, reducing reliance on non-renewable energy sources.

Complementing this is an intelligent energy management system, which monitors and regulates energy consumption.

This smart system cuts energy use and minimizes the brewery’s overall environmental footprint. 

 Advanced filling and packaging technology

KHS has equipped the Foshan brewery with state-of-the-art filling and packaging technology, delivering four turnkey lines to enhance production capacity and efficiency. 

The keg line is a standout, processing up to 90 kegs per hour. It features the Innokeg CombiKeg for keg washing and filling, alongside the Innopal RK robot for advanced palletizing.

This robotic system streamlines operations by managing tasks such as depalletizing, capping, and labelling. 

Two returnable glass lines further enhance the brewery’s capabilities, each capable of outputting 48,000 bottles per hour.

These lines are equipped with the Innofill Glass DRS ECO filler, designed to minimize oxygen pickup and CO2 consumption during the filling process. This ensures high-quality beer production while adhering to sustainability goals. 

The brewery’s canning line is equally impressive, handling 90,000 cans per hour. It employs a patented CO2 purging process that reduces oxygen levels in cans by up to 90%, ensuring superior beer quality.

Additionally, this process consumes significantly less CO2, supporting Carlsberg’s environmental objectives. 

These advanced systems highlight the brewery’s commitment to innovation and sustainability, setting a new benchmark for modern brewing facilities. 

Benchmark for excellence

The brewery’s rapid commissioning impressed Kime, particularly the canning line, which reached 98.5% efficiency within eight days.

“This performance sets a new standard across the entire Carlsberg Group,” he noted. 

The facility will serve Guangdong Province and Southern China, home to 150 million consumers with high purchasing power.

Its product portfolio includes international brands like Carlsberg, Tuborg, and Grimbergen, alongside strong local names such as Wusu and Chongqing. 

This state-of-the-art brewery reinforces Carlsberg’s market presence in China and exemplifies the power of collaboration and sustainable innovation in the beverage industry. 

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