German brewery Rothaus and KHS Coes carry out glass bottle filling
· Innofill Glass DRS is fully upgraded
· Bafu State National Brewery Rothaus becomes the first customer of the new system
· The patent system monitors the filling process and ensures beer quality
All-round upgrade: Recently, Rothaus from Baden-Württemberg chose to use KHS Innofill Glass DRS filling equipment and enjoyed many important new functions. This is because KHS Coes has carried out a series of upgrades to this glass bottle filling equipment. This will provide the brewery with a reliable and high performance beer filling service.
In fact, Innofill Glass DRS is not a new device that has only recently been introduced. Over the years, KHS Coes has provided its customers with mature glass bottle filling technology with this type of filling equipment, and has continuously added new features to meet user needs. However, the filling equipment currently operating at Rothaus AG, the national brewery in Baden-Württemberg, Germany, is very special. This flexible layout of the filling machine has 132 filling valves with a capacity of 50,000 bottles per hour, which reduces the consumption of carbon dioxide and products while cleaning. KHS Coes has significantly improved its equipment in at least four areas with its 150 years of expertise in beer filling.
50,000 bottles per hour
This flexible unit features 132 filling valves with a capacity of 50,000 bottles per hour for hygienic filling while reducing carbon dioxide and media consumption.
Rothaus used this newly purchased equipment to fill bottles of 0.5 litres and 0.33 litres. The quick changeover ensures a high degree of flexibility and line efficiency in the production planning. For this reason KHS Coes offers the latest standard QUICKLOCK hygienic quick-locking system. The bottle guardrail can be switched by some manual adjustments. Thanks to the brackets and the changeovers. The positive fit between the two ensures that it is fixed in place. Therefore, the filling time of the filling machine plus a crown capping machine can be reduced by 33%, as long as 15 or 20 minutes. Ludwig Clüsserath, head of KHS Coes filling technology development, said: "The simple lever knob not only loosens or locks the change piece, but is also durable and resistant to broken glass or chemicals."
132 filling valves
The unique DIAS diagnostic aid system carefully records the filling process. The pressure sensor of each filling valve continuously monitors pressure, time and steps.
In order to prevent the bottle from rupturing at the inlet of the filling equipment, the Innofill Glass DRS is also equipped with the SOFTSTOP system, which has been patented. This compact, hygienic bottle stop system can be activated at full power. Here, the grating measures the bottle spacing during the filling process of the filling device. Secondly, the brake wedge slows the flow rate of the bottle, so that the filling process continues continuously and efficiently, ensuring a stable filling quality. There is no need to change the shape when changing the bottle type. The new stop ramp will not leave scratches on the surface of the bottle and the noise will be lower.
Unique selling point for higher quality
During the subsequent filling process, the unique DIAS diagnostic aid system carefully records the filling process. The pressure sensor of each filling valve continuously monitors pressure, time and steps. In this case, any deviation from the target value can be immediately recognized. In addition, it should be emphasized that in order to ensure a low oxygen intake, vacuuming and carbon dioxide injection processes are monitored. Once the bottle is broken during the entire filling process, it will be detected by the all-round seamless inspection system and trigger the bottle breaking procedure. A pressure graph from the sensor data is displayed on the monitor. Clüsserath said: "In this way, the operator can find out all the faults as soon as possible." In practice, this not only enables fast, targeted repairs and reduces the workload of the operator, but also establishes the basis for preventive maintenance. This data can be used to statistically evaluate the results, based on which the potential source of future errors can be eliminated in advance, which in turn ensures quality stability and operational continuity.
Another important feature is the camera-controlled OPTICAAM high pressure foam control system. The foam produced by HPI will replace the residual oxygen in the bottle, so this is very important for the quality of the beer. Because the foam is dependent on various parameters during the filling process, the new OPTICAM system allows the KHS Coes filling equipment to continuously monitor and adjust the foam layer on the top of the beer without operator intervention. This means that Rothaus can not only prevent the loss of a large amount of beer due to excessive foaming, but also detect and eliminate bottles that are not sufficient. If the error rate is too high, production will stop and the operator can find out the cause of the fault from a clear analysis report.
Through the inclusion of SOFTSTOP, DIAS and OPTICAM, the entire KHS Coes system for Rothaus, through these mechanical and digital system solutions, guarantees the quality of the beer throughout the filling process.