The KS Diaphragm Koex is a multifunctional portioning device in the food sector for processing all pasty and dimensionally stable products with internal filling.

Equipped with a modern drive concept based on a highly dynamic servo motor, a wide variety of food products can be portioned. And this in many sizes and individually configurable ratios of outer shell and filling. The spectrum ranges from mini meat or cheese balls and confectionery to large potato or bread dumplings. The type of filling as well as its consistency can vary - from low viscous sauces to highly viscous emulsions with chunky fillings - everything is possible.

Product injection - so-called coextrusion - thus allows a wide range of design possibilities, not only in terms of the specification and consistency of the two starting materials, but also their filling ratio to each other.

Centrally controlled via KS vacuum fillers of the P-series, the filling machines, portioning device and output conveyor form a single unit. In addition, the motorized height adjustment of the complete diaphragm module offers simple and convenient positioning over a cooking bath.

The central servo concept for all drives ensures precise conveying and portioning with gram accuracy. All functions can be visualized and easily operated on the clearly arranged, swiveling operator terminal.

The specification and size of the product to be manufactured can be modified with just a few quick-change parts.

This guarantees easy cleanability and best hygiene.

The modular design and the flexible combination options of the individual modules ensure efficient, ergonomic work with optimum production capacity utilization.

Innovative hygiene solution for the highest demands: The KS Emulsifier FL175 DSE

As a leading machine manufacturer, KARL SCHNELL GmbH & Co. KG goes far beyond the provision of hardware, software and service. With a clear self-image as a "solution provider", the company presents its latest Emulsifier FL175 DSE, which offers significant added value in the food industry thanks to its sophisticated hygienic design.

The concept includes the consistent implementation of the requirements for a hygienic design in accordance with the latest food industry guidelines.  A highly hygienic universal drive unit, the innovative emulsifying unit and the intelligent Smart Control System are the key components.

The universal drive unit has a maximum drive power of 150 kW and is characterized by a wide speed range between 50 and 4500 rpm with constant torque.

Completely made of stainless steel and certified to protection class IP69, it guarantees the highest hygiene standards.

Low-noise, energy-efficient continuous operation is ensured by the hygienic water cooling and the powerful servo motor. The motor shaft, which can be axially adjusted by ±5 mm, enables application-oriented cutting set adjustment without loss of power over the entire adjustment range.

When it comes to the emulsifying unit, KARL SCHNELL can rely on the world's largest range of cutting systems.

The intelligent combination of several cutting principles in one machine enables the production of homogeneous, extremely fine products in one operation, with minimal wear and maximum process reliability.

This is particularly important in modern production facilities and offers the greatest possible efficiency with minimalproduct losses, especially when cleaning after a product change. 

The optional product feed via a KS feed hopper with integrated screw allows precise temperature control, even with highly viscous raw materials, and also offers a further increase in production speed in the process.

The KS Emulsifier FL175 DSE sets new standards in terms of speed and fineness in the production of food.

The control system includes temperature and system monitoring. This ensures consistent product quality throughout the entire process.  Access is via personalized RFID login for different user levels.  KS Smart Control enables the setting of definable shearing positions and automatic temperature-dependent expansion correction.

Control takes place directly on the emulsifier via PLC and can be seamlessly integrated into a complete system control.

The hygienic design of the control cabinets is standard for KS machines, ensuring trouble-free production even in wet rooms.

This concept is used in almost all areas of the food industry, with a focus on highly hygienically sensitive areas such as baby food and delicatessen production.

SMART FLOW BATCH SYSTEM – The intelligent process solution

Standardizing and simplifying process steps is one of the most important goals for all food producers.

Today, there is more and more overlap between individual product groups and their processing. Just a few years ago, for example, completely different production processes were used for the manufacture of sausages and the production of processed cheese. With the emergence and rapidly increasing importance of vegan foods on the market, new technologies and processes have been devised.

Sustainability by all-in-one machine configuration

With its Process Automats, KARL SCHNELL offers an intelligent solution that enables the production of both meat products and meat substitutes in a compact all-in-one machine.

Since all process steps are integrated into one unit and can be implemented flexibly, the user can design his products and formulations in an almost unlimited variety of ways. In the production of meat alternatives, for instance, there are many different parameters have to be set during the mincing and emulsification of the raw materials with regard to the selection and use of the cutting tools

HMMA-based formulations (meat analogs with a high water content) can mostly be treated in a similar way to classic fine  meat emulsions. Here, the focus is on a perfect bite and a good mouthfeel.

In TVP-based (Textured Vegetable Protein) formulations, importance is placed on a pleasant structure. Here, both the pre-mincing and the fine mincing process must be handled very sensitively in order to achieve the desired uniform particle structure in the defined degree of fineness of the end product.

As the pioneer in emulsification technology, KARL SCHNELL can draw on a wealth of experience and offer a variety of process-specific cutting systems. In combination with other features such as temperature control, evacuation, etc., a high-quality, precise and reproducible result is achieved.

Intermediate cleaning of the machine, even during ongoing production, is performed by the CIP (cleaning in place) connection. The result of this self-contained system is the highest standard of hygiene without contamination or cross-contamination, while at the same time minimizing the consumption of water and cleaning agents.

Energy efficiency by smart process technology

In contrast to conventional systems, KS Process Automats require far less motor capacity when manufacturing a comparable product and, system-related, also have shorter process times. In addition, due to KS Smart Control,

only the required amount of energy is applied into the process that the product can actually absorb.

The KS INNOVATION CENTER in South Germany offers state-of-the-art technology for development, research and training.  A complete machine park for the entire process chain is available - in modular design and with a high degree of automation.

Equipped with Process Automat and Mixer as well as a process line, consisting of Silo, Heating Unit UHT and Creaming Tank.

Both cold and hot processes with pasteurisation or sterilisation can be carried out - using high shear and low shear techniques.

The technological know-how through decades of experience in all areas of food production is decisive responsible for the comprehensive recipe and process development.

The technical and technological expertise at the KS INNOVATION CENTER offers an unlimited variety of processes and recipes - from block cheese to dips, creams, sauces, recombined processed cheese preparations and vegan alternatives - everything is possible.

We offer solutions – not just a product!

The experts in process technology bring you an all new virtual experience.

Discover a whole world of processing possibilities to find the best solution for your production needs.

For over 75 years, KARL SCHNELL has been synonymous worldwide for innovative products made in Germany.

The basis of all our work is a cooperation in partnership.

Our product portfolio is almost completely developed, designed and built in-house. Complex systems are created from individual machines - depending on the task at hand - that can process and manufacture a wide variety of food products. The modular design and the flexible combination options of the individual modules guarantee smooth, ergonomic work and reliable process flow.

So far, our specialists have installed thousands of integrated systems for a clientele that includes both small companies and global corporations and is active in a wide range of industries.

At KARL SCHNELL, we believe that personal contact with our customers is indispensable.

Equally important for us is the efficient access and worldwide networking of expert knowledge - as compactly as possible on one platform. In this respect, the virtual showroom is an excellent extension for live trade shows.

Because the virtual PETFOOD ARENA offers us the unique opportunity to get in touch with part of our customers who cannot be directly on site.

We thus support you in an even better way to develop a solution for your individual needs.

With our new PETFOOD ARENA you can walk through an user friendly environment and explore tailor-made applications, learn about state-of-the-art process flow and see how we can inspire and support you to make your best product ever.