Brief description of the model

Modular technological equipment on a SKID-base for filling kegs with beer or kvass (mild rye beer); production capacity – up to 60 kegs/h; with the following available versions:

• “KEG-Service M60” – basic version;
• “KEG-Service M60-N” – version with optional device for kegs external cleaning.

Purpose of function

Continuous operation mode: cleaning and filling kegs (with «A», «S» or «G» fittings, of 30L or 50L format).

Operation mode

Automatic.

Picture of the Unit

Scope of services

The turn-key base comprising: manufacturing, delivery to the Customer’s address, mounting and installation at the Customer’s production site, start-up and commissioning. 

Scope of delivery

Basic model:

• Keg cleaning and filling unit (with keg tilter);
• CIP-Unit.

Optional equipment:

• Cleaning unit for external surface of kegs.

Video of the equipment functioning 

General description

The Keg Cleaning and Filling Unit is designed for continuous operation with two independent working stations (channels).
The cycle sequence for each channel consists of 6 steps (including 4 steps are operational). Both working stations run simultaneously (in synchronism).
List and description of sequence steps for basic version:

• 1-st: (stand-by) – keg is placed on working bench and its fitting must be aligned with head of working station;
• 2-nd: (operational) – first cleaning of metallic kegs with lye-solution;
• 3-rd: (operational) – second cleaning of metallic kegs with lye and acid solutions;
• 4-th: (operational) – sterilization of metallic kegs with steam;
• 5-th: (operational) – filling with product;
• 6-th: keg moving down to the pallet with keg-tilter.

External cleaning – can be an optional step if the filling unit is completed with Cleaning Unit for external surface of kegs.

• The Keg Cleaning and Filling Unit is mounted on a skid and has the following configuration:
• transportation devices for keg moving step-by-step;
• hold-down clamper with aligning controller;
• cleaning and filling heads (CFH);
• groups of valves for utilities and product flow distribution;
• keg tilter;
• measurement and control devices, temperature and level transmitters;
• switch cabinets (SHU1; SHU2).

The CIP-Unit has the following functions:

• preparation of lye and acid cleaning solutions, with automatic maintaining of preset temperature and concentration;
• storage of cleaning solutions in order to reuse them;
• cleaning solutions feeding to- and return from the Keg Cleaning and Filling Unit, with flow rate control.

Configuration of CIP-Unit:

• tank for storage of lye cleaning solution, with capacity of 260 L;
• tank for storage of acid cleaning solution, with capacity of 260 L;
• tank for accumulation and storage of rinsing water, with capacity of 260 L;
• centrifugal pumps for cleaning solutions and rinsing water – 3 pcs;
• heat exchanger (with steam as heating agent);
• dosing station (with dosing pumps and conductivity transmitters) for preparation and maintaining of preset concentration in cleaning solutions;
• measurement and control devices (pressure, temperature and level transmitters);
• switch cabinet (SHU 3).

Optional equipment - Cleaning unit for external surface of kegs - is a separate autonomous equipment mounted on its skid, consisting of the following parts and components:

• the working bench with aligning bumpers (for placing two kegs);
• flow manifolds with nozzles;
• protection cover (up-and-down motion);
• water feeding unit with circulation tank.

Operation mode - discrete cleaning with circulation and reuse of rinsing water; refill of water flow from the Customer’s utilities pipelines.
The kegs reversible spinning provides equal spraying on all the external surface of kegs.
When the cycle of external cleaning is finished the kegs are transported to the step of the 1-st cleaning with lye solution.

Sequence of technological process (for basic version)

Step number	Step name	Description of operations	Step duration, min
I	Stand-by	1. Accumulation area
II	1-st cleaning	2. Residual pressure check	1 min 30 sec ÷2 min
		3. Remaining product blowing-off
		4. Rinsing with hot water
		5. Cleaning with lye: • direct flow; • reverse flow; • fitting flushing
		6. Filling with lye solution
III	2-nd cleaning	7. Cleaning with lye: • direct flow; • reverse flow; • fitting flushing	1 min 30 sec ÷2 min
		8. Rinsing with hot water
		9. Cleaning with acid: • direct flow; • reverse flow
IV	Sterilization	10. Rinsing with cold water	1 min 30 sec ÷2 min
		11. Blowing-off with steam
		12. Sterilization with steam
V	Filling with product	13. Blowing-off with CO2	1 min 30 sec ÷2 min
		14. Notching with CO2
		15. Filling with product
VI	Tilter	16. Unloading keg from the unit, moving down to the pallet

Sequence of technological process (for version with optional external cleaning of kegs)

Step number	Step name	Description of operations	Step duration, min
I	External cleaning	1. Pre-rinsing and water draining to sewage	1 min 30 sec ÷2 min
		2. Water circulation and return for reuse
II	1- st cleaning	3. Residual pressure check	1 min 30 sec ÷2 min
		4. Remaining product blowing-off
		5. Rinsing with hot water
		6. Cleaning with lye: • direct flow; • reverse flow; • fitting flushing
		7. Filling with lye solution
III	2- nd cleaning	8. Cleaning with lye: • direct flow; • reverse flow; • fitting flushing	1 min 30 sec ÷2 min
		9. Rinsing with hot water
		10. Cleaning with acid: • direct flow; • reverse flow
IV	Sterilization	11. Rinsing with cold water	1 min 30 sec ÷2 min
		12. Blowing-off with steam
		13. Sterilization with steam
V	Filling with product	14. Blowing-off with CO2	1 min 30 sec ÷2 min
		15. Notching with CO2
		16. Filling with product
VI	Tilter	17. Unloading keg from the unit, moving down to the pallet

Note: the sequence of technological process can be modified at Customer’s request. The sequence of technological process is established as one of Terms of delivery in the Purchase Contract.

Key technical features

№	Parameter	Units	Value
1.	Production capacity (for kegs of 50L format)	pcs/h	60
2.	Working capacity (for kegs of 50L format)	pcs/h	up to 80
3.	Number of independent channels (working stations)	pcs	2
4.	Number of technological operations at each working channel	pcs	5
5.	Process temperature of cleaning lye solution	°С	70 ÷ 80
6.	Process temperature of cleaning acid solution	°С	40 ÷ 50
7.	Process concentration of cleaning solutions	%	1 ÷ 2
8.	Pressure of product at the Unit inlet	MPa	0.3
9.	Requirements for the utilities provided by the Customer’s centralized pipelines
	а) cold water (of drinking quality):
	pressure	MPa	0.3
	consumption (max)	m3/h	0.4
	b) hot water:
	pressure	MPa	0.3
	consumption (max)	m3/h	0.6
	c) steam (germ-free):
	pressure	MPa	0.3
	consumption (max)	kg/h	4/0
	d) compressed air for production needs (germ-free):
	pressure	MPa	0.2
	consumption (max)	m3/h	2.0
	e) compressed air (for pneumatic system and control devices):
	pressure	MPa	0.6
	е) СО2 (for blowing-off and notching)
	pressure	MPa	0.2
	consumption (max)	kg/h	2.0
10.	Installed power	kW	14
11.	Power supply voltage	V	380
12.	Dimensions of basic version/with option for external cleaning	mm	4200х3500х2500/ 4200х3500х2500

Basic material of construction – stainless steel AISI-304

Technological control

• check of keg presence at stand-by step;
• check of keg integrity (residual pressure measuring);
• production control: counter of the number of filled kegs;
• check of keg presence at working station (cleaning and  filling head);
• check of keg presence on the tilter;
• check of keg hermetical sealing at working station (cleaning and  filling head);
• check of hermetical sealing of the keg fitting valve;
• dosing accuracy control: filling check by flowmeter;
• control of process temperature of cleaning solutions – by temperature transmitters;
• control of process concentration of cleaning solutions – by conductivity transmitters;
• check of pressure in pipelines with product and utilities (water, steam CO₂, compressed air) at the inlets of the unit.

Note: to ensure the dosing accuracy control by flowmeter it is necessary to install the buffer pressure tank.

Control system functions

• automatic PLC-based control of operation processes at Keg Cleaning and Filling Unit (including optional equipment for external cleaning of kegs) – by switch cabinets SHU1 and SHU2;
• automatic PLC-based control of operation processes at CIP Unit – by switch cabinet SHU 3.

Function modes

• automatic running and functioning of all devices and actuators (valves, pumps, pneumatic and electric drives and gears) according to the sequence of technological process preset by software;
• manual operation – used for maintenance and service (adjustment and check-up of devices and actuators).

Modulation functions

• automatic adjustment of process temperature of cleaning solutions to stay within preset range;
• automatic adjustment of process concentration of cleaning solutions (preparation and maintaining) to stay within the preset range;
• automatic sequence of steps of technological process, according to timers settings;
• automatic stop of productions in case of alarm when the actual parameters are out of preset range: low pressure of compressed air for pneumatic system, pumps malfunction, low level in tanks for lye or acid cleaning solutions, heating element malfunction.

Information functions

• visualization of actual technologic parameters on the operator’s panel;
• visualization of running the sequence of steps of technological process;
• visualization of arrested or malfunctioning components and devices;
• production control of number of filled kegs;
• automatic compilation and logging of daily technological register.

Service functions

• it is possible to edit setpoints of different parameters of the technological process.

Configuration of control system

Industrial PLC by “OVEN-K”; operator’s panel with touch-screen; and pneumatic devices - by “SMC”.

Required operational conditions. Environment impact

The Keg Cleaning and Filling Unit  must be installed in-doors, in heated production departments, with normal ambient temperature (+10 ÷ +25°С) and humidity (up to 75%). It is obligatory to mount in the department a system of exhaust and forced ventilation.
Switch cabinet is made of stainless steel AISI 304, with ingress protection rate IP54 (spray-proof).

The Unit has prearranged optional CIP coupling (can be connected to the central CIP station of the Customer’s plant).

When the Customer observes all the requirements on installation, operation and maintenance of the Unit, the Manufacturer guarantees that:

• level of noise generated by the Unit stays within limits of range admitted by State Standard GOST 12.1.003-83;
• level of vibration generated by the Unit stays within limits of range admitted by State Standard GOST 12.1.012-2004;
• the Unit corresponds to requirements and regulations established by State Standard 12.2.003.-91.

Standard delivery terms

Scope of services:

• Manufacturing and supply to the Customer’s address;
• Installation, start-up and commissioning at the Customer’s site, with training course for the staff.

List of technical accompanying documents:

• Technical passport;
• Operation and maintenance manual;
• Declaration of correspondence to requirements of the Technical Regulations of the Customs Union (TRCU).

Guaranteed operating lifetime – 12 months.

Manufacturing time (readiness for delivery) – up to 110 days.