LIGHTWEIGHT KEYKEG User manual

©Lightweight Containers, May 2015.
Disclaimer: The information contained herein is offered for use at your own discretion and risk. All statements, technical information and
recommendations contained herein are based on tests and data that Lightweight Containers believes to be reliable, but the accuracy or
completeness has not been verified and is not guaranteed. No warranty of any kind is made with respect to any of the above representations.
Instructions for manual filling of KeyKeg
STEP 1: EVACUATE ALL OXYGEN FROM THE INNER BAG
•Remove the blue dust cap.
•Spray some alcohol or other disinfectant on the valve.
•Connect a clean disinfected coupler to KeyKeg and purge
out residual air from the inner bag (entrapped during
manufacturing) by opening the ball valve for at least
6 seconds.
•Disconnect the coupler.
STEP 2: CONNECT FILLING HEAD TO THE BEVERAGE TANK
•Rinse the beverage hose and filling head with alcohol, other disinfectant or sterilize
by steam or in an oven to ensure good microbiological conditions.
•Disinfect all connections.
•Connect the beverage supply to the beverage valve connection.
•Fill the beverage hose completely with beverage by flushing some beverage.
STEP 3: CONNECT FILLING HEAD TO KEYKEG
•Close the air valve of the filling head and once again disinfect the filling head.
•Position KeyKeg on a support in an upside down position.
•Hold the filling head in an inverted position.
•Fill the probe by gently opening the ball valve until beverage foam reaches the
top of the probe to ensure oxygen free filling conditions.
STEP 4: FILLING THE KEYKEG
•Connect the filling head to the container in the inverted position by turning it clock wise until it
stops moving.
•Unlock the handle and push it down until it locks.
•Open the ball valve of the beverage line.
•Gently open the air valve and adjust it to set counter pressure to a level well over the CO2
saturation pressure of the beverage at the given temperature to avoid foaming.
Step 1
Purge beverage bag
CO2/Air Connection

©Lightweight Containers, May 2015.
Disclaimer: The information contained herein is offered for use at your own discretion and risk. All statements, technical information and
recommendations contained herein are based on tests and data that Lightweight Containers believes to be reliable, but the accuracy or
completeness has not been verified and is not guaranteed. No warranty of any kind is made with respect to any of the above representations.
STEP 5: CLOSE THE BEVERAGE VALVE AND DISCONNECT THE FILLING HEAD
•Close the ball valve after the reading of manometer abruptly drops to zero.
•Unlock the filling head and disconnect from KeyKeg by turning to the left.
•Clean the outside of the KeyKeg valve by spraying hot water.
•Disinfect the KeyKeg valve with some alcohol or disinfectant.
•Take KeyKeg from the support and place a snap cap on the KeyKeg closure to make it tamper proof.
IMPORTANT:
•This simple filling procedure does not leave a headspace, the fill level might be slightly over nominal volume.
•To minimize oxygen pick-up, an additional CO2flush of the bag before filling can be considered. Do not fill up
the bag entirely, an amount of approx. 5 litres is sufficient.
•Ensure evacuation of all air from the hose to the beverage supply.
•Ensure good microbiological conditions. Sterilize pressurization head, filling head and beverage hose with
alcohol thoroughly. Sterilize the KeyKeg valve before and after filling (pay attention not to spill alcohol on the
PET sphere as PET can be susceptible to damage by alcohol).
•Before ending the filling procedure, make sure that all air has been evacuated from the backspace. Damage
of the beverage bag will be prevented when it is pressed to the container wall.
•Filling is done in the inverted position to help the inner bag to unfold correctly. The inner bag can burst,
when the container is filled in upright position!
•For (dis)connecting coupler and filling head read the “KeyKeg manual”.
Fill beverage
Drain air
Step 4