FAQ

  Have you ever wondered how these cans get filled with beer? We will guide you through each step of the journey from empty to full and back again. Step 1: Loading the Machine with Empty Cans The process starts with rows of empty cans. Depending on the brewery or copacker’s canning machine, the cans may be fed into the machine in two ways: Automatic canning: In a high-output automated system, a depalletizer is used to load the empty cans onto a conveyor belt in groups. Manual canning: For manual or semi-automatic systems, the operator must feed each empty can into the machine by hand. Regardless of the method, the empty cans arrive on the conveyor belt without tops, ready to be filled. In some cases, copackers may use pre-printed cans to skip the labeling step, but most of the time, the cans are blank, with labels added later. Step 2: Rinsing the Interiors of the Cans The cans are thoroughly washed before filling, whether they are brand new or recycled. They travel down a conveyor belt and into a twist rinser that looks like a rollercoaster for cans. The twist rinser flips the cans upside down and blasts them with sanitizing water, cleaning the interiors, before returning the cans to their upright position. Step 3: Purging the Oxygen As the cans are open, they are full of oxygen and residual water. To remove this, carbon dioxide (CO2) is pumped into each can to purge the oxygen and prevent it from affecting the beer’s flavor and shelf life. Step 4: Filling the Cans After purging the oxygen, the cans are ready to be filled with beer. A Teflon tube descends from above, filling the cans with the desired beer. The number of cans filled at once depends on the size and capacity of the filling station, with more filler heads allowing for more cans to be filled at once. Most machines pour slightly more than the required amount into each can to account for spillage. GX Canning offers end-to-end capabilities to fill 12oz. standard, 12oz. sleek, 16oz. standard cans, and other sizes upon request. Step 5: Adding the Ends The top part of the can, the end or lid, is dispensed from above and clangs onto the open cans. Some setups may have a vacuum sealing machine that sprays nitrogen into the can as the lid is added, expelling any remaining oxygen. Step 6: Seaming the Cans A seamer fastens the end to the rest of the can. Each full can is lifted into the seamer for double seaming, which involves two rollers rotating around the can to crimp the end and can together. Some seamers may drop the end and seam simultaneously. Step 7: Rinsing outside of the Cans To prevent stickiness, the outside of the cans are rinsed to remove any spillage. The cans are then carried into a blow-off tunnel for a quick burst of air to remove any remaining water before they are dried.

 

Managing Dissolved Oxygen in Beer Production
Dissolved oxygen (DO) levels in beer can greatly impact its taste and shelf life. Here are tips for monitoring and minimizing DO levels during the brewing and packaging process to ensure your beer tastes just as you intended.
DO Basics: DO refers to the amount of oxygen incorporated into beer during brewing. The amount of DO can change based on how the beer is handled during and after fermentation. Monitoring DO levels is important, especially for packaged beers that have a longer lifespan.
Measure DO: Testing for DO should be done methodically, starting after primary fermentation and continuing through packaging. Keep a log of DO levels to identify any sources of oxygen in the process. Check for DO at various points in the packaging process and measure temperature, carbonation, and pressure to ensure consistency.
DO in Packaging: DO pickup during packaging can vary due to temperature, pressure, and other factors. Monitor DO levels at various points in the process, including the tank, beer manifold, and both shaken and unshaken cans to determine where oxygen is being introduced.
Minimize DO: To maintain low levels of DO in packaged beer, consider the following:

• Minimize incoming DO in the bright tank
• Check for leaks in hoses and valves
• Keep beer at ideal temperature (34°F/1°C)
• Use degassed water for rinsing/sanitizing
• Control CO2 purges
• Minimize exposure to air during filling.

 

Counter Pressure Craft Can Filling

Here are the main advantages of a counter pressure canning machine over the atmospheric model :

• Product flows from a pressurized tank into a pressurized can;
• Requires a slightly higher investment in filling technology;
• Minimizes CO2 loss and DO pickup;
• Offers precise control over production variables by filling into a purged, sealed container and using easily-adjustable machine parameters;
• Allows for greater flexibility in product range, from still to high-carbonation (up to 4.1 vols) and is less impacted by temperature variations;
• Is the preferred filling method for high-production environments.

 

The Counter Pressure Filler, also referred to as an Isobaric Filler, is a machine designed for the purpose of filling containers such as bottles or aluminum cans with carbonated drinks from a pressurized or non-pressurized bulk storage tank without causing a loss of carbonation. This tool is used by manufacturers of sparkling wines, soft drinks, and brews for bottling their products for retail sales. To operate this device, you will require a primary storage tank suitable for carbonated drinks, a chiller, CO2 storage bottles, and a carbonating unit that can either be integrated with the primary storage tank or function as a separate entity.

The counter pressure filler operates by filling the container through a top-mounted filling tube that is fitted with a diffuser to distribute the liquid evenly around the walls of the container and minimize foaming. The center of the tube features a smaller return tube that allows CO2 to escape to the top of the filling tank, thereby enabling more product to fill the bottle.

An alternative, less commonly used method in automated filling equipment due to its cost and complexity, involves filling from the bottom using a long tube that reaches the bottom of the bottle and a crown seal that secures the bottle once it is filled. Both the CO2 and drink supply lines are connected to the filler, and a vent is included to allow for the release of gas during the filling process. Valves on each input and the vent allow you to control the pressure and speed of filling and venting.