KHS has improved the filler, adding several new features and options, such as a new pressure sensor or optimised high-pressure injection.

Manfred Härtel, filling product manager at KHS, explains: "The KHS Innofill DRS is the first machine to use pressure sensors in every single filling valve to ensure full monitoring of the filling process."

The sensor data is displayed as a pressure graph on the monitor to give operators the chance to detect errors as quickly as possible. In practice, this not only makes repairs easier and relieves operator workloads but also provides a basis for preventive maintenance. This data enables results to be statistically evaluated, to enable future sources of error to be pinpointed in advance. This in turn ensures consistent quality and the continuation of ongoing operation. 

High-pressure injection

In order to minimise the beer's oxygen pickup, in modern filling systems air is forced out of the bottle prior to closure by a jet of water being briefly injected to foam the beer. This foam displaces the oxygen in the bottle, but also causes beer loss. Thanks to foam measurement via a camera and due to the central fill level adjustment unit, the Innofill Glass DRS is said to reliably permit extremely precise filling volumes, thus minimising beverage loss during this process.

The operator no longer has to visually monitor the proceedings as the camera on the crowner checks and records the foam formation. Here, too, the data collected is statistically assessed. Operators are informed by the system if there is either too much or too little foam and badly foamed bottles are automatically channeled out. An intelligent post-regulation unit is also available as an option. Optimised high-pressure injection can be retrofitted – not just on all KHS systems, but also on fillers made by third-party manufacturers. 

Cleaning and filling

Another new feature on the KHS Innofill Glass DRS is the hygienically optimised crowner which is now easier and quicker to clean. For instance, the contact area on the head piece to the capping ring has been reduced. This allows more forceful rinsing and reduces the amount of residual beer on the components. In order to decrease the contact area between the cork shoe and head piece, KHS has enlarged the distance between the two. In addition, a special sealing ring prevents beer entering the thread of the crowner.

Time savings

The shorter conversion times enabled by the new quick-lock system for format parts allow time to be saved, resulting in higher machine availability. A new valve manifold also makes a separate control cabinet superfluous. All process valves and the entire sensor technology are now monitored. The operator can directly recognise the status of the process valves through local status indicators.

Systems supplier KHS has improved hygiene in the surrounding area by doing away with active grease distribution in the filler carousel. The machine is now height adjusted without lubricants; grease distribution is thus no longer required. The redesigned media distributor means that the media storage and lubricant-free process seals in the media feed are physically separated from one another. 

The Innofill Glass DRS is one of many machines KHS has at its disposal for the competent and sustainable installation of turnkey glass, canning or PET lines.