Name: KCA-25D : Machine for the automatic rinsing and filling of kegs 8-25 kegs/hour (with double tank for chemical solutions)
SKU: kca-25D
Availability: BackOrder

Description

Automatic CIP system for the cleaning, sanitizing of the stainless steel kegs and for the filling of carbonated beverages into the kegs

… with two storage tanks for two different sanitizing solutions

… with the manual rotation of the keg between the cleaning and the filling cycle

The KCA-25D is a multifunction machine that includes a device for automatic rinsing of stainless steel kegs and the automatic isobaric filling of carbonated beverages like beer, lemonade, wine or cider into kegs. The equipment is designed for the filling and rinsing of kegs with beer, cider, wine and for other beverages, using by computer control operated valves and a pump. In comparation with the KCA-25 machine the KCA-25D machine includes two tanks and two pumps to sanitation of kegs using both alcalic and acid sanitizing solutions.

Operating capacity :

up to 8 pcs of kegs per hour : all rinsing, sanitizing cycles and the filling cycle
up to 25 pcs of kegs per hour : only rinsing and sanitizing cycles without the filling

The actual capacity of the machine depends on how dirty the kegs are and how long time it has been since they were used. For more dirty kegs, it is necessary to set longer times for individual washing cycles and this reduces the capacity in the number of kegs per hour. If the drink foams more, the time required to fill the kegs also increases (in this case, we recommend lowering the temperature of the drink in the source tank).

The machine is designed for cleaning and filling kegs with a volume from 15 to 50 liters.

The working performance is :

Two cycles : the rinsing cycle & the sanitation cycle : the maximal performance 25 kegs per hour ( with volume of 50 liters).
Three cycles : the rinsing cycle & the sanitation cycle & the filling cycle : the maximal performance 8 kegs per hour ( with volume of 50 liters).

The device is controlled by a PLC – it is possible to individually change the time of each cycle. Inserting of kegs is manual, removing of kegs after finalizing of filling cycle is manual. The computer opens and closes all valves, switches on the pump and controls a temperature of the sanitizing solution automatically as well. The machine is equipped with an integrated reservoir for the alcalic sanitizing solution.

Sterilized compressed air is needed for flushing inner space of the keg, which can contain of the rest of water or sanitizing solutions.
We recomment to use an external hot steam-generator as optional accessories to ensuring perfect sterilization of the inner walls of the kegs and shorter cleaning and sanitation cycle.

Material is stainless steel AISI 304.

Description :

Valve	Type	Description
1.1	Elmg G1/2“ 24V NC	Cold water inlet
1.2	Elmg G1/2“ 24V NC	Hot water inlet
1.3	Elmg G1/2“ 24V NC	CO2 inlet
1.4	Elmg G1/2“ 24V NC	Air (compressor) inlet
1.5	Elmg G1/2“ 24V NC	Product inlet (Beer)
1.6	Elmg G1/2“ 24V NC	Steam inlet (180°C max)
1.7	Elmg G3/4“ 24V NC	Return to the tank Z1
1.8	Elmg G3/4“ 24V NC	Return to the tank Z2
1.9	Elmg G3/4“ 24V NC	Discharge from the barrel into the sewer
1.10	Elmg G1/2“ 24V NC	Discharge from the barrel to the foam tank
1.11	Elmg G3/4“ 24V NC	Suction from tank Z1
1.12	Elmg G3/4“ 24V NC	Suction from tank Z2

Part number	Type	Description
		Standard equipment
T1	Thermal probe PT100	Temperature measurement in the tank Z1
T2	Thermal probe PT100	Temperature measurement in the tank Z2
S1	Heating element 2200W	Heating of the tank Z1
S2	Heating element 2200W	Heating of the tank Z2
M1	Pump Ebara 70/05	Main pump
SP	Sick LFV200	Flow sensor
		Additional equipment (for surcharge – only for demand)
SC	Conductivity probe	Measuring of conductivity
M2	Dosing pump 1	Dosing of sanitation to tank Z1
M3	Dosing pump 2	Dosing of sanitation to tank Z2
PV	Steam generator	Integrated steam generator

The device operates in the following cycles:

An emptying the keg (automatic)
A depressurization the keg (automatic)
Flushing the keg with cold water (automatic)
Flushing the keg with alcalic sanitizing solution (automatic)
Flushing the keg with hot water (automatic)
Flushing the keg with acid sanitizing solution (automatic)
Flushing the keg with hot water (automatic)
Steam sterilization of inside of the keg – it requires an external source of steam (automatic)
Filling the keg with carbon dioxide gas (automatic)
Rotation of the keg 180 degrees (manually)
Filling the keg with beer (semi-automatic)

The first connection :

1. DO NOT CONNECT THE MACHINE TO THE POWER SUPPLY until you succesfully progress to the step 6. The spiral heater will be burned down (will be destroyed) if the steps are not followed in exact order.
We do not hold the warranty in case you burn down the heating spiral.
2. Connect media according to the description on the device.
3. Fill the rear tank with sanitizing solution (6% solution of caustic).
4. Connect the KCA-20D unit to the air distribution system – minimal pressure 4bar.
5. Set the air pressure on reducing valve on range between 2.0bar up to 2.5bar.
6. Set the carbon dioxide pressure to 2bar using the CO2 reducing valve.
7. Connect KCA-20D unit to the power supply 3ph 400V/50Hz .

Description of keg rinsing and filling step by step:

This description is valid only for the manual mode. The KCA-25D machine provides all steps automatically excluding steps from 16 to 17 – manual filling of the keg.

1. All valves are closed
2. Connect the filling coupler on the keg
3. Overturn the keg and place it on the KCA-25D unit
4. Open valve 1.8 (waste) and valve 1.2 (air). The rest of content in the keg is drained.
5. Valve 1.8 (waste) remains opened, close valve 1.2 (air) and open valve 1.4 (cold water).
That is the first rinse of the keg. Time of rinse will vary depending on total volume and degree of pollution of the keg.
6. Close valve 1.4 (cold water), valve 1.8 (waste) remains open.
7. Valve 1.8 (waste) remains open, open valve 1.2 (air). Water is forced out of the keg by air. Time may vary depending on the total volume of keg.
8. Close all valves. Open valve 1.7 (caustic), turn on the pump. The caustic sanitation of keg is in progress. Time may vary depending on the total volume of keg. The valve 1.2 (air) may be opened to improve the scattering of sanitation solution.
9. Turn off the pump and open valve 1.2 (air). Cycle of returning the caustic to caustic tank runs.
10. Close all valves.
11. Open valve 1.8 (waste), open valve 1.3 (hot water). Rinse until the keg is completely deprived of caustic (usage of pH meter is recomended). The valve 1.2 (air) may be opened to improve the scattering of hot water.
12. Close valve 1.3 (hot water), valve 1.8 (waste) remains open, open valve 1.2 (air). Hot water is forced out of the keg by air. Time may vary depending on the total volume of keg.
13. Close all valves. Open valve 1.1 (CO2) and open valve 1.8 (waste). Air is forced out of the keg by CO2 gas. Time may vary depending on the total volume of keg.
14. Close valve 1.8 (waste), valve 1.1 (CO2) remains open. Fill the keg with CO2 until the inner pressure is 1.8 bar. The inner pressure is controlled by pressure regulator.
15. Close all valves.
16. Put the keg on the floor, open valve 1.6 (beer) and open valve 1.9 (outlet of CO2 from keg). Keg is being filled by beer, filling speed is controlled by pressure regulator. When he beer foam starts flowing from pressure regulator, the keg is full.
17. Keg is sanitized now, filled with beer and ready to be shipped to your customer.

Filling of the 50L beer keg takes from 1 to 4 minutes – the time depends on the chosen overpressure in the keg and in the beer storage tank, temperature of beer, beer type and other physic influences.

Technical parameters :

Maximum performance : rinsing & sanitation		20-25 (depending on foamicity of beer)
Maximum performance : rinsing & sanitation & filling		6-8 (depending on foamicity of beer)
Volume of kegs maximum [ liters ]		50
Inserting and removing kegs		manually
Pneumatic connection – pressure sterile air		min. 4bar
Electrical connection		3x400V /50Hz 16A
Heating		1x 2.2 kW
Pump		2x 750 W
Control panel		230V / 50Hz
Alcalic solution tank with dosing		1x 50 liters
Acid solution tank with dosing		1x 50 liters
Switching between modes : washing – filling		auto
Sterilisation mode with hot steam (optionally)		external steam
Width / mm /		1200
Depth / mm /		800
Height / mm /		1900
Weight /kg/		150
Dimensions and weight for transport on a wooden pallet		1200 x 1200 x 2200 mm / 220 kg
Average delivery time / months / (after first advance payment)		2
Material		AISI 304

Software :

The program allows several modes :

Sanitation / filling – automatic process of the keg chemical sanitation with filling the keg
Sanitation – automatic keg chemical sanitation process without filling the keg
Filling – automatic filling the keg without sanitation
Disinfection – chemical disinfection of the filling valve and the foam collectioning reservoir

Language : English, Czech. Other languages available for individual demand for a surcharge

Media and connections :

Connections to pipelines :

Steam – thread G1/2″
Beer – thread G1/2″ / hose 12/7×9.5mm
CO2 – thread G1/2″ / hose 12/7×9.5mm
Compressed air – thread G1/2″ / hose 9.5×6.7mm
Hot water – thread G1/2″ / hose 12/7×9.5mm
Cold water – thread G1/2″ / hose 12/7×9.5mm

The connection to the pipelines can only be carried out by persons who are familiar with the properties and function of the pressure vessel and are also familiar with the relevant regulations for its operation

Input media

Hot steam
minimum pressure 3 bar
maximum pressure 5 bar
maximum temperature 160°C

Cold water

minimum pressure 2,5 bar
maximum pressure 4 bar
recommended temperature 8-12°C

Hot water

minimum pressure 2,5 bar
maximum pressure 4 bar
recommended temperature 80°C

Pressure air

minimum pressure 6 bar
maximum pressure 8 bar
must not be contaminated by
– humidity – dry air
– solid particles (oil)
– microorganisms (sterility)
(Only oil-free air compressor with very fine air filtration and air dryer can be uses … see recommended air compressor and filtration bellow)

Carbon dioxide CO2

recommended pressure : from 0.5 bar up to 1.0 bar
(From the pressure bottle with carbon dioxide)

Beverage product

Beer, cider, wine, juice, lemonade etc (beverage to be filled into kegs)
minimum pressure 2 bar
maximum pressure 3 bar

Sanitizing chemical solution :

As a sanitizing solution, we recommend using a NaOH alkalic solution with a maximum concentration of 3%
The total volume of the tank is 150 l
The filling volume is 125 liters – calculate the concentration on this volume (in the factory settings, the heating temperature of the sanitation solution is set to 60°C, if necessary, this value can be changed in the control application settings)

Electrical connection

Power supply 3+PEN, 50Hz, 400V, TN-S
Installed input power 4.7kVA
Control voltage 24 VDC
The filling unit is fitted with a CYKY5x2.5 connection cable in length 5m, the end of a plug socket 400V 16A
The connection to the electrical network can only be carried out by persons who are familiar with the characteristics and function of the pressure vessel and are also familiar with the relevant regulations for its operation

Available keg couplers – the filling heads :

That’s how the filling valve looks – all types A, D, G, M, S, U are available according to requirement of the customer :

Recommended set of spare parts … price € 1200,-

The set includes :

2 pcs x electric heating spiral …. € 82,- / pc
2 pcs x gasket for EBARA CDX pump … € 120,- / pc
1 pc of the solenoid valve or 1 pc of the pneumatic valve …. € 270,- / pc
2 sets x hoses and couplings …. € 120,- / set
2 sets x filling head for kegs …. € 140,- / set

Recommended accessories :

Conductivity sensor … € 1300,-

The IFM LDL220 conductivity sensor (measure range of 0.1 – 1 000 mS/cm ) for monitoring of current condition of the chemical solutions. The conductivity of chemical solutions is displayed on the PLC display.

MESG-06S : Micro electric steam generator 6kW 0.5bar (8 kg/h) … € 1090,-

The steam generator is necessary for the final keg sterilization after the chemical cleaning. The price includes also a hose connection between the keg washing machine and the steam generator.

Powerful steam generator with heating capacity of 6 kW for extra heavy continuous load operation. These robust models in a stainless steel case have exceptional steam generating capabilities thanks to the unique Teflon technology on the heating spirals. Output capacity is up to 8 kg of steam per hour at pressure 0.5 bar and temperature 111°C.

Micro electric steam generator 6 kW 0.5 bar (9 kg/h)

ACO-350-200OF : Oil-free air compressor 21.0 m3/h (350 l/min) with pressure tank 200 liters

Since air is also used in the individual steps of sanitation, it is necessary that this air be sterile, free of moisture and not contain any residues of solid particles or oils that have escaped into the air distribution system from the compressor.

Piston air compressor of the oil-free Pro Line Zero series. Machine output 350 l/min (21.0 m3/h) at 3 kW, power supply 3-phase 400V/50Hz. Compact lightweight oil-free piston air compressor with direct drive with a maximum air pressure of 10 bar and an air pressure tank with a volume of 200 liters. Automatic run control using Condor’s superior pressure switch. Minimal machine maintenance.