PolyKeg PRO User manual

INSTRUCTION MANUAL
POLYKEG PRO
MI01 Rev. 07 dated 06/08/2020
This document is property of PolyKeg®S.r.l. - Unauthorized copying and use is strictly forbidden.

INDEX
This manual contains information, instructions and warnings for proper handling and use of the
PolyKeg PRO one-way keg.
MI01 Rev. 07 dated 06/08/2020
This document is property of PolyKeg®S.r.l. - Unauthorized copying and use is strictly forbidden.
SECTION 1
Warnings 3
SECTION 3
Valves and couplers 7
SECTION 5
Sanitizing instructions 14
SECTION 4
Logistics data sheet 9
SECTION 8
Tapping instructions 25
SECTION 9
Depressurization
instructions
28
SECTION 10
Dismantling instructions 30
21
SECTION 7
POLYKEG PRO WITHOUT BAG
Filling instructions with
PolyKeg®manual kit
5
SECTION 2
Packing and keg
identication
16
SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with
PolyKeg®manual kit
SECTION 11
Materials and
symbols sheet
34

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SECTION 1
Warnings

MI01 Rev. 07 dated 06/08/2020
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SECTION 1
Warnings
The PolyKeg PRO one-way keg is intended for professional use only. Please refer to this Instruction Manual and the symbols
on the keg before use.
When handling the keg, wear personal protective equipment (goggles, gloves, etc.) and make sure the room where you are
working is ventilated.
Make sure the keg is intact and leave the warnings on the keg clearly readable.
If used improperly the PolyKeg PRO keg may be damaged, not ensuring the integrity of the product or causing injury and/or
property damage.
The PolyKeg PRO one-way keg cannot be reused, should not be released into the environment and should be depressurised
immediately after use and disposed of empty at authorised collection points.
0÷35 °C - 32÷95 °F
Keep away from heat sources.
If exposed to temperatures above the
permitted limit the keg may be damaged,
not ensuring the integrity of the product
or causing injury and/or property damage.
HAZARD
Suocation hazard.
Use in a well-ventilated environment.
MAX 3.5 BAR - MAX 50 PSI
If over-pressurized, the keg may cause
injury and/or property damage.
NO CHEMICALS
Keep away from unsuitable chemicals
or cleaning substances. The keg may
be damaged, not ensuring the integrity
of the product or causing injury and/or
property damage.
NO CHILDREN
Keep away from children.
When the keg is under pressure it is
heavy and can cause injury
and/or property damage.
NO DIRECT SUNLIGHT
Do not expose to direct sunlight.
The keg may be damaged, not ensuring
the integrity of the product or causing
injury and/or property damage.
DO NOT ROLL
Do not roll and/or drop.
The keg may be damaged causing injury
and/or property damage.
DO NOT REMOVE
Do not remove and/or tamper with the
valve. The keg may be damaged, not
ensuring the integrity of the product or
causing injury and/or property damage.
DO NOT PIERCE
Do not pierce and/or cut.
The keg may be damaged causing injury
and/or property damage.

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SECTION 2
Packing and keg identication

MI01 Rev. 07 dated 06/08/2020
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SECTION 2
Packing and keg identication
PALLET STANDARD IDENTIFICATION
VALVE AND KEG IDENTIFICATION
POLYKEG s.r.l.
Via Pietro Nenni, 51 24050 Calcinate (BG) Italy
Ph. [phone]
KEG000835
POLYKEG PRO 30L SILVER A - type valve
24/04/2020 15.06
Batch: P01L1900855B001 Quantity: 44
(240) KEG000091 (37) 0036 (10) P01L1900855B001
CODE
DESCRIPTION
PRODUCTION DAY / HOUR
BATCH / QUANTITY
VALVE SERIAL NUMBER
KEG SERIAL NUMBER

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SECTION 3
Valves and couplers

MI01 Rev. 07 dated 06/08/2020
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SECTION 3
Valves and couplers
TYPE VALVE COUPLER NOTES
AFlat
G
M
SEuropean
Sankey
DAmerican
Sankey
KKK

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SECTION 4
PolyKeg®PRO
logistics data sheets

MI01 Rev. 07 dated 06/08/2020
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SECTION 4
PolyKeg®PRO logistics data sheets
PALLET 80X120 CM |31.50’’X47.24’’
EMPTY KEGS PALLETIZATION
WARNINGS
Possibility of stacking pallets and the maximum number of layers must take into account the mechanical properties of the keg as specied on the technical
data sheet, local regulations, means of transport, handling methods of handling, as well as the conditions of storage areas.
Kegs are supplied on pallets, wrapped with white extensible lm for better protection.
*Quantities refer to three layers palletization, compulsory for CTR 20 ft Standard.
PALLET 100X120 CM |39.37’’X47.24’’
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers 54444
Kegs per layer 20 20 20 16 12
Kegs per pallet 100 80 80 64 48
Height 2077 mm |81,77‘’ 2044 mm | 51,91‘’ 2396 mm | 94,33‘’ 2384 mm | 93,85‘’ 2384 mm | 93,85‘’
QUANTITY pallet kegs kegs kegs kegs kegs
CTR 20 ft Standard 101000 800 600* 480* 360*
CTR 40 ft High Cube 222200 1760 1760 1408 1056
CTR 45 ft High Cube 26 2600 2080 2080 1664 1248
Truck 13,6 mt 26 2600 2080 2080 1664 1248
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers 54444
Kegs per layer 15 15 15 12 11
Kegs per pallet 75 60 60 48 44
Height 2077 mm |81,77‘’ 2044 mm |51,91‘’ 2396 mm |94,33‘’ 2384 mm |93,85‘’ 2384 mm |93,85‘’
QUANTITY pallet kegs kegs kegs kegs kegs
CTR 20 ft Standard 11 825 660 495* 396* 363*
CTR 40 ft High Cube 24 1800 1440 1440 1152 1056
CTR 45 ft High Cube 32 2400 1920 1920 1536 1408
Truck 13,6 mt 32 2400 1920 1920 1536 1408

MI01 Rev. 07 dated 06/08/2020
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PALLET 80X120 CM |31.50’’X47.24’’
FILLED KEGS PALLETIZATION
WARNINGS*
Possibility of stacking pallets and the maximum number of layers must take into account the mechanical properties of the keg as specied on the technical
data sheet, local regulations, means of transport, handling methods of handling, as well as the conditions of storage areas.
To overlap pallets, the load must be evenly distributed using either a rigid interlayer or an inverted pallet. It is recommended to wrap the kegs on pallets with
white extensible lm for better protection.
SECTION 4
PolyKeg®PRO logistics data sheets
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers 3* 2* 2* 2* 2*
Kegs per layer 15 15 15 12 11
Kegs per pallet 45 30 30 24 22
Height 1307 mm |51,45” 1098 mm |43,22” 1274 mm |50,15” 1268 mm |49,92” 1268 mm |49,92”
Stacking in storage
Layers 3+3 2+2 2+2 2+2 2+2
Stacking for transport
Layers 3+2 2+2 2+1 2+1 2+1
Wooden interlayer
120 cm | 47,24"120 cm | 47,24"
1,5 cm
0,59"
80 cm
31,49"
3 cm | 1,18"

MI01 Rev. 07 dated 06/08/2020
This document is property of PolyKeg®S.r.l. - Unauthorized copying and use is strictly forbidden. 12Instruction manual -PolyKeg Pro |
WARNINGS*
Possibility of stacking pallets and the maximum number of layers must take into account the mechanical properties of the keg as specied on the technical
data sheet, local regulations, means of transport, handling methods of handling, as well as the conditions of storage areas.
To overlap pallets, the load must be evenly distributed using either a rigid interlayer or an inverted pallet. It is recommended to wrap the kegs on pallets with
white extensible lm for better protection.
PALLET 100X120 CM |39.37’’X47.24’’
FILLED KEGS PALLETIZATION
SECTION 4
PolyKeg®PRO logistics data sheets
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers 3* 2* 2* 2* 2*
Kegs per layer 20 20 20 16 12
Kegs per pallet 60 40 40 32 24
Height 1307 mm |51,45” 1098 mm |43,22” 1274 mm |50,15” 1268 mm |49,92” 1268 mm |49,92”
Stacking in storage
Layers 3+3 2+2 2+2 2+2 2+2
Stacking for transport
Layers 3+2 2+2 2+1 2+1 2+1
Wooden interlayer
120 cm | 47,24" 120 cm | 47,24"
1,5 cm
0,59"
97 cm
38,18"
3 cm | 1,18"

MI01 Rev. 07 dated 06/08/2020
This document is property of PolyKeg®S.r.l. - Unauthorized copying and use is strictly forbidden. 13Instruction manual -PolyKeg Pro |
SECTION 4
PolyKeg®PRO logistics data sheets
LOADING RECOMMENDATIONS
PALLET 80X120 CM |31.50’’X47.24’’
PALLET 100X120 CM |39.37’’X47.24’’
pallet plan view
CTR 20 ft Standard 11
CTR 40 ft High Cube 24
CTR 45 ft High Cube 32
Truck 13,6 mt 32
pallet plan view
CTR 20 ft Standard 10
CTR 40 ft High Cube 22
CTR 45 ft High Cube 26
Truck 13,6 mt 26
WARNINGS
When transporting lled kegs, it is recommended to use refrigerated containers.
When using refrigerated containers, the number of pallets may vary.
To overlap pallets, the load must be evenly distributed using either a rigid interlayer or an inverted pallet. In order to prevent damage to the kegs and/or falls,
the pallets must be secured with straps and airbags must be inserted in the empty spaces.
The maximum number of layers/kegs must consider the mechanical properties of the kegs as indicated on the technical data sheets, local regulations, means
of transport and handling methods, as well as the condition of the storage facilities.

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SECTION 5
Sanitizing instructions

MI01 Rev. 07 dated 06/08/2020
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SECTION 5
Sanitizing instructions
Hot water
Steam
SANITIZING WITH AUTOMATIC AND SEMI-AUTOMATIC MACHINES
Maximum pressure
on the valve
0,8 BAR
Maximum
temperature
85°C
Max
time
5 SECONDS
Maximum pressure
on the valve
0,8 BAR
Maximum
temperature
100°C
Max
time
3 SECONDS
SANITIZING THE POLYKEG
MANUAL FILLING KIT
Soak the disassembled components of the manual lling
kit in one of the sanitizing solutions listed above. Please
follow the above dilution rates and timescales.
SANITIZING OF THE COUPLER AND
THE EXTERNAL PART OF THE VALVE
Clean and spray the external surface of the components
with one of the sanitizing solutions listed above. Please
follow the above dilution rates and timescales.
AUTOMATIC/SEMI-AUTOMATIC MACHINE SANITIZING
Before starting the lling sanitize the automatic/semi-
automatic lling machine.
SANITIZING THE EXTERNAL PART OF THE VALVE
Set the ller to sanitize the external surface of the keg
valve with hot water or steam according to the above
mentioned pressure, temperature and time values.
WHAT NEEDS TO BE SANITIZED
Before starting the filling, sanitize the manual filling kit (tubes, valves, seals, couplers, etc.) or the automatic/semi-automatic
fil-ling machine. Before connecting the keg, clean and sanitize all parts likely to come into contact with the product (coupler
and external part of the valve). After each filling, clean and sanitize the keg valve. Should it be necessary to temporarily
disconnect the keg, clean and sanitize the external part of the valve.
Note We do not recommend the use of chemicals not mentioned in the user manual. Please pay attention to the composition of the chosen product.
SANITIZATION WITH MANUAL FILLING KIT
Peracetic acid solution in demineralised water
Min time
30 SECONDS
OR
Hydroalcoholic solution in demineralised water
OR
Min
Max 2%
1%
Min time
45 SECONDS
Min 20%
Max 50%

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SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with
PolyKeg®manual kit

MI01 Rev. 07 dated 06/08/2020
This document is property of PolyKeg®S.r.l. - Unauthorized copying and use is strictly forbidden. 17Instruction manual -PolyKeg Pro |
SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with PolyKeg®manual kit
Before lling, please refer to the warnings in the “Section 1” of the PolyKeg PRO
instruction manual and to the keg technical data sheets.
Fig. 1
Gas tube
Pressure top-up connection
Pressure top-up gauge
Pressure gauge
Gas regulator connection
Counter-pressure regulator
Product tube
Product lling connection
Product lling valve
Keg coupler (Micro Matic is recommended)
1
2
3
4
5
6
7
8
9
10
1
7
8
9
10
2
3
4
5
6

MI01 Rev. 07 dated 06/08/2020
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SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with PolyKeg®manual kit
1. Sanitizing
4. Gas and product tube
connection
Disassemble the PolyKeg® lling kit
and sanitize the components as
indicated in the “Sanitizing
Instructions”section.
FIG. 1
FIG. 4
FIG. 2
FIG. 5
FIG. 3
FIG. 6
Connect the product and gas
tubes to the lling kit.
PREPARATION
2. Assembly
5. Gas and product tubes
connection with K-valve
3. Gas and product
pressure check
6. Product tube purging
Reassemble the kit properly and
close all valves.
K-VALVE ONLY
Connect the product and gas tubes
to the lling kit. Open the red valve.
Check that the pressures of the lling
system are correctly set and below
the maximum value indicated.
(3.5 bar).
Work with the product valve to
remove any residual gas from the
product tube. Close the product
valve.
MAX 3.5 BAR
MAX 50 PSI
CO2
N2

MI01 Rev. 07 dated 06/08/2020
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SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with PolyKeg®manual kit
7. Sanitizing
9. Counter-pressure
regulation
10. Filling 11. End of lling
8. Connection and Counter-Pressure Check
Before lling, sanitize the parts in
contact with the product as indicated
in the “Sanitizing instructions”
section.
Work with the gas valve until the
desired counter pressure is reached
(approx. 0.5 bar lower than the
product lling pressure).
Open the product valve to start
lling and work with the
counterpressure regulator to set
and/or change the lling speed.
Once the nominal lling volume is
reached, close the product valve. Do
not exceed the nominal lling volume
to prevent the product from leaking
out of the bag.
Make sure the lling head is properly connected to the valve, lower the lever and
check the internal pressure of the keg.
FIG. 9
FIG. 8.1 - A-M VALVES FIG. 8.2 - S-D VALVES FIG. 8.3 - G-K VALVES
FILLING
FIG. 10
1.5 BAR
FIG. 11
FIG. 7

MI01 Rev. 07 dated 06/08/2020
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SECTION 6
POLYKEG PRO WITH BAG
Filling instructions with PolyKeg®manual kit
12. Pressure balance 13. Uncoupling
14. Valve sanitizing 15. Seal application
Close the regulator and work
on the gas valve to increase the
counter-pressure to a value
slightly higher than the product
lling value.
Quickly lift the lever and disconnect the coupler from the keg.
Remove any residual product with
water and sanitize the external
part of the valve as indicated in the
“Sanitizing instructions” section.
Apply the seal.
FIG. 13.1 - A-M VALVES FIG. 13.2 - S-D VALVES FIG. 13.3 - G-K VALVESFIG. 12
FIG. 14 FIG. 15