Keg Filling Guide
Our kegs can be filled using a range of different methods, from hand filling, semi-automatic and fully automatic filling, through to existing steel keg lines. We work with a host of global filling machine manufacturers and can help you select the right equipment for your needs.
Manual Filling
Before filling, ensure that the filling head and all pipes are clean and sterilized, and purge the relevant inlet with inert gas. The keg must be in a stable, vertical position throughout the process. Eye and ear protection, together with work wear should be used.
1. To begin:
Flat Type Fitting: A:
- Slide the filling head completely onto the fitting and push down the handle. Fully cover the dispense head before pressing down the handle to avoid damage
Triangle Type Fitting: A:
- Push the filling head onto the fitting
- Holding the fitting with one hand, turn the filling head until it stops and push the handle down
Well Type Fittings: S, D:
- Push the filling head into the fitting
- Turn the filling head until it stops and push the handle down. Too much force can damage the fitting
2. Counter Pressure:
- Kegs are supplied already pre-purged with N2 and the O2 left in the keg is guaranteed to be below 0.2%
- The pressure in the keg will be within 1.0 to 1.5 bar, depending on country of manufacture. (Please contact your local Petainer representative for further information.)
- Close the gas out valve (3) and wait for keg to pressurize
- Then close the "gas in" valve (1)
- Note: ideally the keg should be pressurized at 0.5 bar/7psi below the filling pressure. A manometer can be used
3. Filling:
- Ensure that the "gas in" valve (1) is closed.
- Open the "product in" valve (2) slowly to allow the product to flow into the keg
- Control the filling speed and foaming throughout the fill by adjusting the gas out "valve (3)"
- Note: The filling pressure should not exceed 3,1 bar / 45 psi
- If an accurate fill is required, it is recommended filling the keg on a scale
4. End of Filling:
- Note: It is recommended to leave a headspace at the top the keg of at least 200ml / 8.5 floz
- Once the keg is determined to be full either by weight or by level:
- Close the "gas out" valve (3) followed by the “product in” valve (2), then lift up the handle
- Turn the filling head counter-clockwise (S,D,G)/slide the head off (A) and remove it
- Clean and disinfect the fitting with recommended 70% ethanol
- Put a snap-cap / dust-cap on the fitting
- For Classic only: place the keg in the box. If circumstances allow, use filling temperature above the dew point or acclimatize the kegs before placing in the box
Semi & Automatic Filling
Petainer Kegs can be filled on many suitably modified steel keg fillers. Please contact the filling machine supplier for advice, format parts and program modifications. When using the Petainer Keg Hybrid format, please note the following:
1. Safety
- All machinery must be guarded in accordance with local regulations
- Eye and ear protection, together with work- wear should be used
- PET Kegs can get damaged by sharp objects
- Under-filled Kegs or other rejects should be depressurised prior to disposal, using the Pressure Release Tool (PRT) supplied. Additional tools can be ordered through Petainer
2. Machine Program
- Modify the machine program in accordance with the instructions below:
- All steel keg washing and sterilising functions need to be inhibited, including the “head seal check” and the spear adapter moving, except on the filling head
- Keg must be filled volumetrically to the required capacity to provide head space
3. Racker Conversion
- Check that the filling head spear adapter (piston top) dimensions comply with the Petainer closure drawing and the fitting is exactly centered over the filling head (piston top). Failure to do so may damage the closure and prevent its proper operation!
- Maximum allowed top load (clamp pressure) is: 2000 N (450 lbf) with at least 0,5 bar / 7 psi in the keg
4. Intermediate Head Rinsing
- If the racker design allows, it is desirable to flush/disinfect the filling head and each keg valve from outside before and after filling
- e.g with hot water (1 second at 85°C / 185 F)
- The maximum water pressure should be no more than 0,5 bar / 7 psi higher than the pressure in the keg
- Water pressure after filling should not exceed the pressure in the keg
Keg Washing
Traditional Steel Kegs require keg washing equipment. All one-way kegs come pre-washed, meaning no extra keg cleaning equipment is needed.
The keg is pre-purged with inert gas and does not require internal cleaning. Petainer Kegs can be filled on semi & fully automatic filling lines. In both cases, the filling machines should be sterilized in line with guidance from the machine suppliers. Full filling instructions for semi and automatic fillers are available on request.
This will ensure that anything coming in to contact with the keg and liquid will be prepared.
Clean Machine Fill Every Time
- Clean and spray the fitting & external part of the valve with an ethanol based disinfectant. Observe disinfectant exposure times.
- Ensure that the automatic/semi automatic filler is sanitized in line with manufacturer's instructions.
- Intermittent head rinsing can be performed with hot water only -not steam: 1 second; 85°C / 185 F. The maximum water pressure should be no more than 0,5 bar / 7 psi higher than the pressure in the Keg.
Disinfectant to use: 70% Ethanol *
*Acidic disinfectants can damage the fitting 70% Isoproyl Alcohol (IPA) also appropriate
Disclaimer: Petainer accepts no responsibility for the use of chemical substances or alcohol based solutions in the factory. Always follow your company's health and safety guidelines.