KARL SCHNELL GmbH & Co. KG
About us
PARTNER TO THE FOOD INDUSTRY – We offer solutions, not just a product!
KARL SCHNELL is a globally recognized premium brand in food processing technology with more than 75 years of experience in mechanical engineering “Made in Germany.”
As a family-owned company based in Baden-Württemberg, we develop and manufacture innovative, fully automated process systems and individual machines for the food industry.
Our tailor-made solutions cover the entire production process – from raw material handling to filling – for meat products, pet food, processed cheese, delicatessen products, and modern protein alternatives.
KARL SCHNELL stands for innovation, quality, reliability, and efficient turnkey solutions worldwide.
Address
Muehlstr. 30
73650 Winterbach
Germany
E-mail: ks@karlschnell.de
Phone: +49 7181 9620
Internet: www.karlschnell.de
Contact person:
Claudia Kaesser
E-mail: ks@karlschnell.de
Products & Services
Customized Solutions for Food Processing
KARL SCHNELL develops and manufactures complete processing systems and individual machines for the food industry. Depending on product, capacity and available space, individual components can be combined into automated and continuous processing lines.
The portfolio covers the complete process chain – from raw material handling and size reduction to mixing, emulsifying, heating, buffering and filling.
KS Breakers are designed for the size reduction of frozen product blocks such as meat, vegetables, fruit and cheese and can be integrated into continuous processing lines.
KS Grinders process fresh and frozen products at different temperatures while maintaining the desired raw material structure. The KS Combi Grinder allows fresh and frozen meat to be processed simultaneously.
The KS Mixer Program covers capacities from 30 to 7,000 liters and offers various configurations for mixing different food products.
KS Emulsifiers are used for fine size reduction and emulsification in a wide range of food applications.
KS Process Automats combine cutting, mixing and emulsifying in one machine and are available for batch sizes from 30 to 1,400 liters.
KS UHT Technology enables continuous ultra-high-temperature processing up to 145°C, with capacities from 100 to 6,000 kg/h.
KS Filling Systems with internal gear pump technology provide controlled and gentle product transfer for filling and portioning applications.
KS Transporting & Buffering Equipment includes Lifting Devices, Conveyors, Storage Bins and Feed Hoppers for product handling and continuous material flow.
All systems can be configured according to product characteristics, production volume, process requirements and available space – as complete lines or individual solutions.
More than just a mixer – the KS MixMaster Process System
More than just a mixer – the KS MixMaster Process System
High-end solution for modern production processes
The KS MixMaster Process System from KARL SCHNELL is far more than just a conventional mixer – it is an innovative process centre for the flexible, efficient, and high-quality processing of a wide variety of food products. Developed for the demanding requirements of the food industry, this system combines the advantages of a low-shear mixer with an integrated high-shear emulsifier, fed by a pump directly below the mixing vessel. This opens completely new process possibilities – from gentle premixing to precise emulsification under high vacuum.
Innovative functionality meets maximum flexibility
The KS MixMaster Process System is specially designed for the processing of highly viscous and shear-sensitive products under vacuum. The combination of low-shear mixing and high-shear emulsifying enables products to be processed particularly homogeneously, gently, and efficiently. Dry substances can be effectively dispersed in liquids – without clumping and with high uniformity.
Flexibly selectable process paths:
Conventional further processing: The mixture is transferred to a connected buffer tank and continuously fed to the downstream production unit.
Direct emulsification: The integrated product pump conveys the premix directly under vacuum to the emulsifier, which processes the product into a homogeneous emulsion using the high-shear method, and then transfers it to the further production process.
Recirculation and combination: After emulsification, the product can be pumped back into the mixing tank to be refined with coarse additives. The product is then discharged directly via bypass into the buffer tank and from there into further production.
This system architecture combines the advantages of a process automat with the strengths of a mixer, offering unprecedented process control. Thanks to the controlled pump feed to the emulsifier, precise temperature control is guaranteed – under vacuum conditions, which is crucial for product quality. This allows even sensitive formulations to be implemented reliably and reproducibly.
Benefits at a glance:
• Combination of mixing and grinding technology in one system
• Modular design for maximum adaptability to individual process requirements
• High-vacuum process control that improves product quality and shelf life
• Flexible further processing depending on requirements
• Efficient emulsification and homogenisation, even for complex products
• Precise control of temperature, mixing intensity and product flow
Complementary aspects of the KS mixer portfolio
The KS MixMaster Process System is part of a comprehensive portfolio from KARL SCHNELL, which includes mixing systems in a wide range of sizes and configurations – from 30 to over 7,000 liters. Thanks to intelligent PLC control, separate motor control, vacuum intake for powder components, and precise temperature control, all production requirements can be reliably met. Its reproducibility and integration into continuous production lines make the system an ideal solution for the highest demands on quality and efficiency.
Conclusion
The KS MixMaster Process System offers a unique combination of flexibility, process reliability, and efficiency. It is ideal for producers who demand the highest quality while simultaneously producing complex products economically – a true centre of innovative food processing
Smart up your production – visit us at the German Pavilion Sheikh Saeed Hall S1-H59
Discover other innovative solutions from KARL SCHNELL and find out more on our homepage www.karlschnell.de
KS Process Automats - Modern processing for smart product ideas
Innovation as a success factor
The development and introduction of innovative recipes and products is becoming increasingly important for producers of meat products, processed cheese applications and vegan alternatives. In order to exploit the full potential offered by the success factor of innovation, a modern, flexible machine park is required, together with a high level of technological know-how. This is the basis for a real competitive advantage and a successful product launch.
Reproducible, consistent quality is essential for producing this type of high-quality food. Furthermore, gentle processing and precise ingredient dosing are required in this sensitive area to achieve the best possible flavor in the final product.
All-In-One Solution Process Automat
KS Process Automats offer maximum process reliability and efficient production flow - with significantly reduced batch times and low energy requirements.
State-of-the-art ergonomic agitator tools mix and homogenize the individual ingredients of the formulation sustainably - without lump formation in the shortest possible time. The desired degree of emulsification can be freely adjusted. When processing fine emulsions, the use of the integrated emulsifier is indispensable and particularly effective.
In order to cope with the large number of different applications, the product temperature can be set with direct or indirect temperature control. The use of the vacuum system also guarantees permanent evacuation of the product during processing.
In addition to the automatic metering of additives from different silos and containers, complete integration of the machine control into an existing higher-level plant control system is also possible. This ensures that the product to be produced is delivered to the desired location in the desired quantity at all times. A wide variety of recipes can be stored in order to react flexibly to different products or product changes. The high degree of automation ensures precise, reproducible food production.
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.
The automation in processing ensures standardisation. This guarantees the production of a wide range of permanently high-grade products in constant quality. In addition, it enables producers to react always with flexibility to the market and to position themselves optimally for the future.
Smart up your production – visit us at the German Pavilion Sheikh Saeed Hall S1-H59
Discover other innovative solutions from KARL SCHNELL and find out more on our homepage
Innovative hygiene solution for the highest demands: KS DSE-Series Emulsifiers
As a holistic solution provider, KARL SCHNELL is setting standards in terms of hygiene, efficiency and precision in the ultra-fine comminution of food with the new DSE-Series. The machines combine state-of-the-art technology with an uncompromising hygienic design, thus offering clear added value for demanding production environments.
Hygienic design according to the latest standards
The DSE-Series consistently meets the latest hygiene guidelines of the food industry. The modular motor unit is made of stainless steel and certified to protection class IP69 – ideal for use in wet rooms. The hygienic water cooling and energy-efficient, low-noise continuous operation guarantee maximum operational reliability.
Powerful drive
With a maximum power of 150 kW and a variable speed range from 50 to 4500 rpm with constant torque, the universal drive unit offers maximum flexibility for a wide variety of applications. The axially adjustable motor shaft enables precise and loss-free adjustment of the cutting set during operation – for optimal knife positioning and minimal wear.
Versatile emulsifying unit
Benefit from the world's largest range of cutting systems and the unique ability to combine different cutting principles in one machine. This enables the production of homogeneous, ultra-fine products in a single operation – with the highest performance and maximum process reliability.
Hygienic Cutting System HCS
For particularly hygienically sensitive applications, KARL SCHNELL offers the world's first CIP-cleanable multistage cutting system HCS. The system sets new standards in the area of product safety, particularly with regard to the prevention of bacterial contamination and cross-contamination.
The HCS was designed for the gentle processing of low to medium viscosity, non-abrasive and short-fibre products. Typical applications include the production of delicatessen, baby food, ice cream, cream cheese and processed cheese.
The complete unit consists of a modular cassette housing optimised for CIP cleaning with an integrated bladeless special cutting set and a high-performance sealing system.
Cleaning takes place in a closed state, eliminating the need for blade changes and cutting set disassembly and ensuring continuous operation.
Precise regulation with KS Smart Control
The intelligent control system continuously monitors temperature and system status and enables definable shear positions as well as temperature-dependent automatic expansion correction. Different user levels are managed via personalized RFID login. Control is carried out directly on the machine via PLC and can be seamlessly integrated into existing systems.
Optional product feed
The optionally available KS Feed Hopper with integrated screw ensures precise temperature control – even with highly viscous materials – and further increases production speed.
Available in two versions: FD and FL – optimally adapted to specific requirements.
KS DSE-Series Emulsifiers – for maximum hygiene, top product quality, and efficient processes in food production.
Smart up your production – visit us at the German Pavilion Sheikh Saeed Hall S1-H59
Discover other innovative solutions from KARL SCHNELL and find out more on our homepage
Production lines from KARL SCHNELL - process competence from a single source
The food market is changing quickly. Consumer demands are evolving rapidly – and with them, the demands placed on producers. Today, greater product variety, smaller batches, short response times, and, at the same time, economical large-scale production with consistently high quality are required.
Your line – your success
KARL SCHNELL offers the ideal answer to these requirements: fully automated, highly flexible, and individually designed production lines for food processing. All components are optimally coordinated – for maximum efficiency, process reliability, and product quality.
Suitable concepts for every challenge
From raw materials to finished filling, KARL SCHNELL develops sophisticated line concepts with breakers, grinders, mixers, conveyor technology, and high-performance emulsifiers. Decades of experience and a high level of vertical integration enable system configurations that are impressive even in confined spaces and for special product requirements.
More performance. More possibilities.
Innovative KS high-performance vacuum fillers and flexible buffer solutions ensure a continuous production flow. For specialty products or small operations, KARL SCHNELL also offers a wide selection of high-performance individual solutions.
Freedom for your ideas.
With innovative controls, easy operation, and modular expansion options, you remain flexible at all times and ready for new market trends. And for individual requirements, we deliver equally high-performance tailor-made solutions – customized, efficient, and reliable.
Smart up your production – visit us at the German Pavilion Sheikh Saeed Hall S1-H59
Discover other innovative solutions from KARL SCHNELL and find out more on our homepage
KS Diaphragm Koex - The solution for filled products!
KS Diaphragm Koex - The solution for filled food products!
With the KS Diaphragma Koex, KARL SCHNELL presents a versatile and ultra-modern portioning machine that has been specially developed for processing pasty and dimensionally stable food products with internal filling.
Thanks to an innovative drive concept with a highly dynamic servo motor, products in a wide variety of sizes and shapes can be portioned precisely - from mini meat or cheese balls and confectionery to large-format potato dough and bread dumplings. The fillings are just as variable and range from liquid sauces to highly viscous emulsions with chunky ingredients.
Maximum flexibility through coextrusion
The integrated coextrusion technology enables maximum flexibility in the processing and design of the products. The specification, consistency and filling ratio can be customised to meet a wide range of requirements.
Perfect integration and ease of use
Centrally controlled via the KS P-Series Vacuum Fillers, all modules - from the filling machine to the portioning unit and the output conveyor - work together seamlessly. The electromotive height adjustment of the entire diaphragm module facilitates precise positioning, e.g. above a cooking bath.
A clear, swivelling control terminal enables intuitive control and visualisation of all functions. Changes in specification and product size can be made with just a few, quickly exchangeable parts - an advantage that further optimises cleanability and hygiene.
Modularity and Efficiency
The modular design of the KS Diaphragm Koex ensures maximum efficiency and ergonomics. Flexible combination options for the individual modules ensure optimal production utilization and adapt to the specific requirements of food production.
KS Diaphragm Koex – for high-quality, creative, and precisely manufactured food products.
Smart up your production – visit us at the German Pavilion Sheikh Saeed Hall S1-H59
Discover other innovative solutions from KARL SCHNELL and find out more on our homepage www.karlschnell.de
