Future-proof kegging equipment

“In redesigning the Innokeg Contikeg and Combikeg, we’re demonstrating that KHS is a strong technological partner to the keg business and continues to supply its customers worldwide with powerful, future-proof plant engineering,” says Tobias Wetzel, CSO of KHS. KHS has pursued a clear objective with this further development, he continues. “We’re taking our durable, tried-and-tested keg technology into the next generation. It fully satisfies the high expectations of our customers with respect to hygiene, safety, security and ergonomic operation. It also meets all requirements for maximum line availability, high production reliability and long-term competitiveness.” He sees high growth potential for this equipment on the South American and Asian markets in particular.

Precise process control for gentler product handling

The Innokeg Contikeg washes and fills up to 1,200 kegs per hour fully automatically using the continuous carousel principle. It’s constructed to enable a continuous process flow: the kegs run through all production stages in the machine in rotary operation without having to be decoupled. This makes for a high level of performance and process stability. The Innokeg Contikeg can process kegs holding between five and around 58 liters. It’s thus suitable for a broad range of products – from whiskey soda, beer and mixed beer beverages through wine to water, soft drinks and juice.

KHS makes use of its Direct Flow Control (DFC) filling system for especially resource-conserving filling and gentle product handling. Unlike standard market procedures that regulate the filling speed by increasing the CO₂ pressure in the container, the KHS system precisely controls the flow rate using the DFC valve. This reduces CO₂ consumption by up to 40% and facilitates controlled, foam-free filling.

Modernization focuses on proven strengths

Efficiency is further increased by the use of an integrated, equally established central distributor, explains Stefan Schuhriemen, head of the KHS Keg Technology Product Center. “This controls the media feed from a central point, thus reducing the number of individual valve switches needed in the core process. Accordingly, this makes the system less complex, minimizes wear and enhances process stability.”

KHS has also fundamentally redeveloped the machinery’s media supply. A new valve manifold already deployed in KHS’ filling technology portfolio replaces the previous L-shaped media transfer. The standardized use thereof across various segments makes operation and maintenance easier and improves the global availability of spare parts.

Efficient operation and high line availability

The Innokeg Contikeg is intuitive in its operation. The fully-automatic, high-performance machine is operated from KHS’ tried-and-tested ClearLine HMI operator panel. This localizes disruptions with absolute precision, making troubleshooting easier. It also boosts line availability. The new messaging system has the same effect: if there’s a fault on one of the racking heads, the machine only shuts this head down – fully automatically. Racking continues without interruption – unlike on linear machines, where the failure of just one station can bring the entire process chain to a halt. 

The new IO-Link technology also significantly simplifies diagnostics and maintenance: if a sensor fails, the system accurately locates the disruption. Following manual replacement, this automatically transfers all parameters to the new sensor. The machine can then quickly resume production.

Hygienic line design for sensitive beverages

KHS has also consistently further developed the Innokeg Contikeg with regard to its hygienic design. Here, the systems supplier has applied its proven washing concept, in which the hydromechanical cleaning process uses pulsating sprays with up to three different chemical cleaning media for sanitation. The incorporated soaking function proves its worth when cleaning critical interior keg areas especially, such as fittings and spring assemblies. “During the redesign, we paid particular attention to hygiene. We’ve simplified the wiring by integrating a new valve manifold and thus eliminated possible risks factors here. Hygienic line design is especially critical when processing sensitive beverages such as low- and no-alcohol or NoLo beers, as these make extremely high demands of microbiological safety,” Schuhriemen emphasizes.

Up-to-the-minute line safety and cybersecurity

A thoroughly upgraded safety and security concept completes the Innokeg Contikeg optimization package. KHS meets the latest requirements made of machine and operator safety with numerous adaptations to the engineering – from optimized safety switches on the doors through improved CO₂ extraction to new protective housings.

The revamped machine complies with the current DIN EN 415-2:2025 standard relevant to all machines and already satisfies the requirements of Regulation (EU) 2023/1230 on machinery, effective as of January 2027, and the EU’s Cyber Resilience Act. “As a machine and systems manufacturer, we’re obliged to provide proof of the conformity of our products with valid EU standards and regulations. This forms the basis of the CE mark and goods entry on the European market,” Schuhriemen says.

Cybersecurity is also increasingly gaining significance regarding issue of the CE mark. In the future, manufacturers must provide proof that their products are protected against digital attacks. The regulatory basis for this includes not only the Cyber Resilience Act but also the Radio Equipment Directive with their specifications for IT and OT security.

KHS’ plug-and-produce Innokeg Combikeg – that fits into one shipping container – is also based on the latest technology. Unlike its big brother, it combines the entire line in a single compact machine and caters for a lower capacity range. It therefore provides its customers with a system that’s especially low on space and quick to integrate – and that already accounts for the provisions of the forthcoming EU machine regulation and Cyber Resilience Act.