BFSA4-250...Bottling machine has four rinsing nozzles and four filling head with filling nozzles and...

Czech Brewery System s.r.o., Kolofíkovo nábřeží 30, 747 05 Opava, Czech Republic / Site no 1 WEB : http://www.czechbrewerysystem.com , e-mail : [email protected]

Operation manual for use

BFSA4-250

The semi-automatic machine to rinsing, filling and capping of bottles : 150-250pcs per hour

http://eshop.czechminibreweries.com/product/bfsa4-250/


The BFSA4-250 is the semi-automatic machine to rinsing, filling and capping of bottles with capacity 150-250pcs of

bottles per hour

Main parameters :

Operation capacity: 150-250 bph (depending on fill temperature and the operator, calculated for bottles 330

ml)

Designed for : natural or carbonizated beverages (beer, wine, cider, soft drinks, water)

Type of bottles : Glass bottles (330 ml or 750 ml)

This machine is an original Czech made product.

Features :

Suitable for the filling of carbonized wine, beer, cider, soft drinks and water in glass bottles.

The lifting of the bottles is done pneumatically using an integrated air compressor.

Contact parts made from 304 stainless steel

Stainless steel support table

Transparent protection guards to ensure maximum safety for the operator in case of bottle breakage.

Special filling nozzle to reduce foaming comes as standard

Machine on 4 wheels, to make machine moveable.

Follows CE regulations

Description of the operation cycle :

1. The operator manually inserts, empty bottles upside down into the throat of the nozzle which is used to

sanitize bottles.

2. After pressing the button, the bottle is cleaned and sanitized by sanitation solution. The sanitation sequence is

automatically, consecutively repeated 3 times.

3. Subsequently, the operator removes the bottle and positions them on the table under the filling needles

(depending on the size of the bottle, it is possible to adjust the height of the table under the filling needles, so

that the filling needles be fully inserted to a particular bottles – setting of the table is done manually) .

4. In the next step by pressing of button “filling” needles go automatically down and land on the bottles. If the

bottling line works properly, the operator has always achieved the same level of beverage in all filled bottle,

which is done by special design of the filling needles.

5. Subsequently, the operator removes the filled bottles and put them on the table. Then the crown caps will be

applied on bottle using an integrated machine to capping of bottles.

The basic functions of filling machine:

1. Rinsing of the bottles by sanitizing solution

2. Beverage filling into bottles

3. Capping of the bottles


Technical specifications of the machine:

Bottles are rinsed by sanitizing solution before beverage filling. Rinsing process is automatically done after

the operator push the button “rinsing”.

Sanitizing solution is mainly based on oxygen. Bottles are manually inserted into the rinsing dishes with

spraying nozzles upside down.

After rinsing phase, operator manually puts the bottles on a table under the filling nozzles.

Bottling machine has four rinsing nozzles and four filling head with filling nozzles and one pneumatically

operated head to capping bottles.

Usually operator can use the bottles with volume from 330 ml to 750 ml, in case of a larger volumes it is

necessary to consult it with the manufacturer.

Level of the beverage in the bottles can be set individually. Design of the filling nozzle ensures that all bottles

will be always filled on the same volume of the beverage.

It is possible to fill natural beverages or carbonated beverages (like water, mineral water, limonades, beer,

cider, sparkling wine) directly from the tank.

The bottling line is equipped with a diaphragm pump, which pumps the beer from the serving tank to the

integrated buffer tank of the bottling machine (the amount of beer in the storage tank is monitored by level

switches) if level in the storage tank drops to a minimum level then pump automatically starts to drawdown

the beverage from external tank.

Pressure in the storage tank of the bottling line is set by the user according to the pressure in the beer tank.

Line is designed as movable with 4 stainless steel casters with possibility to be braked on place.

Capping head – for crown caps – it is pneumatically operated.

Phase of rinsing, filling and capping is performed automatically after pressing the button by operator, refilling

of beer storage tank is done automatically.

Bottling line is equipped with very quiet oil-free air compressor.

Material AISI 304 – stainless steel.

Connection of the bottling line with an external beer tank by flexible hose – the hose is not included.

Type of connection can be customized – either clamp, DIN or SMS.

Machine can be completely sanitized (washed) within the sanitation process that allows complete washing and

sanitizing all routes, hoses and pipes of the machine.

Well trained staff is able to fill the from 200 up to 250 bottles of 330 ml per 1 hour.

Technical parameters :

Output 150-250 bottles per hour depending on fill temperature, type of the bottles and

the operator

Bottle specs: Max diameter 120mm – Max height 350mm

Power connection : Single phase 230V / 50Hz

Power consumption 0.37 kW

Air consumption 6 bars – 120ltr per minute

Dimensions: 0.88m x 0.74m x 2.37(h)m

Weight : 120kg


Basic dimensions:


Basic operation instruction – how to use bottling line ?

1. Assembly:

- installation of the intake tank (accumulation tank for beer) on the filling rail

- connection of the hose from diaphragm pump

- connection of the exhaust pipes at the bottom


- cable connection level sensors (as marked)

It is necessary to remove the fixing straps from the filling rail and the capping head, that were

installed there only for transport.

Place the machine on a flat and firm base.

Secure the brakes on the transport casters of the filling machine.

2. Preparation for the bottling machine use

- switch on the machine by the main switch (all other switches of electric cabinet must be switched

off)

- check that the compressor is on - the red button is pulled out (when the machine is switched on, the

compressor automatically switches on), while checking the button on the pump, whether is in

position ON.

Red button of pump

Main switch of bottling line

Red button of compressor

- fill with a sanitizing liquid (2% solution) the sanitation capacity in the rear part.

- Attention! Do not use acid solution more than 5%, since there is a risk of damage to the sealing

gaskets and the pump membrane.


- close the sanitization tank with a valve and open the valve on the air line of the manometer (at the

factory, the equipment has a pressure of 2 bar)

- carry out of cleaning of bottling line - see section 7. SANITARY CLEANING

- after the sanitation please connect the diaphragm pump inlet with the beer tank by using of flexible

hose.

- Attention! It is necessary to carry out the filling of bottles at a low temperature of beer in tank. We

recommend 1-3 ° C, in order to avoid foaming.

- - connect CO2 pressure vessel with accumulation tank of bottling line (ready-to-drink tank) (circuit

diagram)

- Warning !!! you have to set at the pressure regulator of CO2 pressure vessel (6) the same pressure

like is in beer tank (CCT) (4)

- Warning !!! In order to avoid frozen of pressure regulator of CO2 bottle, it is necessary to install

pressure regulator for CO2 bottle with heating !


Recommended assembly diagram of the bottle filling system :

1 – butterfly valve of beer tank (CCT)

2 – Y-filter of bottling line

3 – diaphragm pump of bottling line

4 – beer tank - CCT

5 – pressure gauge of beer tank

6 – pressure regulator of beer tank (recommended to use with heating)

7 – intake beer tank of bottling line

- Switch on the BLOW MAN for 2 seconds to blow the air from the intake tank

- open the butterfly valve of beer tank (1) and turn on the PUMP ON pump (on main electric cabinet)

(always switch on again for 2 seconds BLOW MAN, because the pressure in the intake tank will smoothly

arise)

- the pump then automatically fill the beer into the MAX level of intake beer tank

- adjust the bottle holders so that when inserting the bottle into the holders the bottle neck is under the cap

- to fix the for capping the bottle holder, so that in order to have the neck of the bottle under the capping

head


- Install a protective plexi-glass. This glass will protect operator during the filling.

3. Rinsing of bottles

- put all 4 bottles upside down in washing bottles holders

- Pressing the RINSING button on the front control panel, the rinsing of bottles will be executed


4. Filling of bottles

- install a bottle stand under the filling tubes (see photo)

- set the desired height of the stand according to the size of the bottle (before filling, the filling tube

should be inside the bottle)

ATTENTION!!! It is very important so that the bottle stand would be installed horizontally with

filling rail of bottling line in order to avoid possible block of filling heads.

Always fill only 4 bottles together, it is impossible to fill just one bottle.

(The distance between the bottle stand and the filling needles must be the same for all bottles)

Remark: For beverage with CO2, before starting of the filling, it is necessary to set a large number of air

exhausts cycles by using of switch BOTTLE – to 0.5L and at the same time a longer filling time will be set. If

the beer does not foam during filling, then the amount of air exhausts and filling time can be reduced.

Attention! It is necessary to carry out the filling of bottles at a low temperature of beer in tank. We

recommend 1-3 ° C, in order to avoid foaming.

On the control panel, you can see the position of the beer level in the intake tank MAX LEVEL and MIN

LEVEL. The level is indicated by light.


5. Capping of bottles (crown caps)

- insert the crown cap in the capping head (a magnet is installed in the capping head to hold the crown

cap in right position)

- put the filled bottle in the cap holder (hold the bottle by the bottom part), press the CAPPING button

on the control panel. The bottle will be capped.

Attention! Do not drop your fingers under the capping head during a capping operation, it could cause

serious injury

6. End of filling phase

- close the butterfly valve of the beer tank (CCT) and turn off the diaphragm pump with the PUMP

ON/OFF switch (the intake tank of bottling line will not be filled in with beer)

- after the discharging of intake beer tank and filling rail – you should fully clean the bottling line with

a sanitizing and disinfecting solution and finally with pure water (see section 7. SANITATION)

7. Sanitation and cleaning phase

- Solutions used for cleaning and disinfecting of the bottling line.

- For washing of the bottling line is generally used the same sanitation process like for any

technologies in brewery - alkali (two percent solution of NaOH). Tanks and pipelines are washed

with a hot (65°C) solution of alkali. Never use for washing of the technologies warmer water or caustic solution over 65 ° C !

Peracetic acid is used for disinfection.


- insert the rinsing bath on the bottle holder under the filling heads

- the hose that goes from the rinsing bath, put in a container with a sanitizing disinfectant solution


- the same please add into the sanitation tank the air hoses of air exhausts

- Insert a hose that is connected with pump into the container with sanitation liquid


- disconnect the hose from the storage tank (via check valve) and connect it to the upper part of the

storage tank, via pressure gauge (see picture below).

- switch on the pump by switch “PUMP MAN” and switches “FILLING MAN” and “BLOW MAN”. Then

sanitation solution start to be pumped into the intake water tank (there is spraying ball) and through filling

needles is returned back into the stainless steel rinsing bath and then discharged (by gravity) into the plastic

barrel with sanitation solution…the diaphragm pump is self-priming! Pump is able to take the sanitation

solution by itself.

- the sanitation solution (liquid) circulates from the plastic barrel (which is part of the line) to the line

via spraying ball in intake tank, then via filling needles and back to the plastic barrel.

- after cleaning process with the sanitizing solution is necessary to rinse the bottling line with cold

water in the same way !


8. Organization of the workplace (photo).

- in the blue box, you can see washed bottles


8. Safety rules – during the working with bttling line

- The electrical connection may only be carried out by an authorized person!

- Use protective equipment while working and familiarize yourself with the safety precautions when

working with chemical sanitizing solutions.

Attention ! It is strictly recommended to use a protective equipment when working with lye

as goggles and rubber gloves, lye is caustic!

- the machine can only be operated only by one person (operator), the operator should always be

familiar with this operating manual before using the bottling machine

- the machine contains pneumatically controlled mechanical parts, there is a risk of injury, do not

touch to the pneumatically operated elements during operation

- when rinsing bottles (RINSING) do not stand over bottles in washing holders, there is a risk of face

attack with sanitizing liquid. Use face shield or glasses!

- never touch the machine during the filling phase (FILLING)

- during the capping process (CAPPING) hold the bottle only at the bottom, do not insert the hand

below the capping head (risk of serious inquiry)

- it is necessary ALWAYS rinsed and filled only 4 bottles, never only 1 bottles, machine can be

damaged

- do not unnecessarily use water on the electrical parts of the machine

- once per 1 month lubricate moving parts of pneumatic cylinder by lubricant suitable for food and

beverage industries. Loctite LB 8105 is recommended


9. Support

Contact details:

In case of any problems or question please contact technical support of supplier: +420 732 217 950 , e-mail :

[email protected]

Our Number: +420 732 217 950

Czech brewery system s.r.o.

Central production and office address :

Czech brewery system s.r.o.

Kolofíkovo nábřeží 30

74705 Opava

Czech Republic

VAT CZ05783011

Opening hours: Monday – Friday, 7:00 to 16:30 (Prague time zone)

BFSA4-250...Bottling machine has four rinsing nozzles and four filling head with filling nozzles and...

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