PolyKeg PRO KEG000835 User manual

LIGHT AND STRONG
INSTRUCTION MANUAL
POLYKEG PRO
MI01 Rev. 13 dated 30/01/2023

INSTRUCTION MANUAL
POLYKEG PRO
INDEX
Warnings
SECTION 1 3
Packing and keg identification.
SECTION 2
Valves and couplers
SECTION 3
Logistics data sheet
SECTION 4
Sanitizing instructions
SECTION 5
POLYKEG PRO WITHOUT BAG
Filling instructions with
PolyKeg® manual kit
SECTION 7
Tapping instructions
SECTION 8
Depressurization instructions
SECTION 9
Dismantling instructions
- with equipment
- with key
SECTION 10
Materials and symbols sheet
SECTION 11
POLYKEG PRO WITH BAG
Filling instructions with
PolyKeg® manual kit
SECTION 6
5
21
25
28
30
37
7
9
14
16
This manual contains information, instructions and warnings for proper handling and use of the
PolyKeg PRO one-way keg.
pag. 2PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
WARNINGS
SECTION 1

pag. 4
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, must not be disposed of in the environment, must be
depressurized immediately after its use and returned empty to authorized collection points in compliance with
local regulations.
WARNINGS INSTRUCTION MANUAL
SECTION 1
0÷40°C
32÷104 °F
MAX 3,5 BAR
MAX 50 PSI HAZARD
NO CHILDREN NO DIRECT
SUNLIGHT
NO CHEMICALS
DO NOT
REMOVE
DO NOT ROLL DO NOT
PIERCE
KEEP AWAY
FROM VITAL
PARTS OF THE
BODY
USE OF VISOR
OR
PROTECTIVE
SCREEN
USE OF CUT
RESISTANT
WORK GLOVES
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.
If over-pressurized, the keg may
cause injury and/or property damage.
Suffocation hazard.
Use in a well-ventilated environment.
Keep away from children.
When the keg is under pressure it is
heavy and can cause injury
and/or property damage.
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.
Keep away from chemicals or
unsuitable cleaning substances. The
keg may be damaged, not ensuring
the integrity of the product or causing
injury and/or property damage.
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 roll and/or drop.
The keg may be damaged causing
injury and/or property damage.
Do not pierce and/or cut.
The keg may be damaged causing
injury and/or property damage.
Whenever using or handling,
keep the keg away from vital parts of
the body
Always use personal safety equipment
whenever using the keg
(e.g. handling, connecting and
disconnecting, depressurising, etc.).
Always use personal safety equipment
whenever using the keg
(e.g. handling, connecting and
disconnecting, depressurising, etc.).
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
PACKING AND KEG
IDENTIFICATION
SECTION 2

pag. 6
PACKING AND KEG IDENTIFICATION
SECTION 2
PALLET STANDARD IDENTIFICATION
VALVE AND KEG IDENTIFICATION
CODE
CODE QUANTITY BATCH N. PALLET
DESCRIPTION
DATE / PRODUCTION TIME. / PACKING/ PALLET ID
BATCH / QUANTITY
DAY OF PRODUCTION
(GREGORIAN CALENDAR)
KEG TYPE
(WITH BAG OR WITHOUT BAG)
VALVE TYPE
PRODUCTION LINE
PRODUCTION PLANT
PRODUCTION TIME
YEAR OF PRODUCTION
PRODUCTION ORDER
POLYKEG s.r.l.
Via L. da Vinci 5/9, 24064 Grumello del Monte (BG)
Italy
Tel. [phone]
KEG000835
FUSTO POLYKEG PRO 30L ARGENTO valvola A
00 PALLET120X80 - 4424/04/2020 15.06
Lotto: P01L1900855B001 Quantità: 44
(240) KEG000835 (37) 0044 (10) P01L1900855B001
S - BAG
00-000 00:00:00 00
P00L00000000
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
VALVES AND
COUPLERS
SECTION 3

pag. 8
VALVES AND COUPLERS
A
G
M
S
D
K
FLAT
EUROPEAN
SANKEY
AMERICAN
SANKEY
KK
SECTION 3
TYPE VALVE COUPLER NOTES
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
POLYKEG PRO LOGISTICS
DATA SHEETS
SECTION 4

pag. 10
POLYKEG® PRO LOGISTICS DATA SHEETS
SECTION 4
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz 24 L 811 oz. 30 L 1014 oz.
Layers 5 4 4 4 4
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‘’ 93,85‘’ 93,85‘’
| | 2384 mm |2384 mm |
QUANTITY pallet kegs kegs kegs kegs kegs
CTR 20 ft Standard 11 825 660
CTR 40 ft High Cube 24 1800 1440
1920
1920
1920
495* 396* 363*
1920
1440 1152 1056
CTR 45 ft High Cube 32 2400 1536 1408
Truck 13,6 mt 32 2400 1536 1408
EMPTY KEGS PALLETIZATION
PALLET 80X120 CM | 31.50’’X47.24’’
PALLET 100X120 CM | 39.37’’X47.24’’
Palletization
12L 406 oz. 16L 541 oz. 20L 676 oz. 24L 811 oz. 30L 1014 oz.
Layers 5 4 4 4 4
Kegs per layer 20 20 20 16 12
Kegs per pallet 100 80 80 64 48
Height 2077 mm|81,77‘’ | | | 2384 mm|
QUANTITY pallet kegs kegs kegs kegs kegs
CTR 20 ft Standard 10 1000 800 600* 480* 360*
CTR 40 ft High Cube 22 2200 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
WARNINGS
Any stacking of pallets and the maximum number of layers must take into account the mechanical properties of the keg as reported on the
technical data
sheet, the local regulations, and the means and manner of handling and transport, as well as the conditions of the storage areas.
Kegs are supplied on pallets, wrapped with white extensible film for better protection.
*Quantities refer to three layers palletization, compulsory for CTR 20 ft Standard.
2044 mm 51,91” 94,33” 93,85” 93,85”
2396 mm 2384 mm
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

3*
15
45
3+3Layers
Layers
Wooden interlayer
120 cm 120 cm
80 cm
1,5 cm
3+2 2+2 2+1 2+1 2+1
2+2 2+2 2+2 2+2
2*
15
30
2*
15
30
2*
12
24
2*
11
22
1307 mm 51,45” 1098 mm 43,22” 1274 mm 50,15” 1268 mm 49,92” 1268 mm 49,92”
pag. 11
POLYKEG® PRO LOGISTICS DATA SHEETS
SECTION 4
FILLED KEGS PALLETIZATION
PALLET 80X120 CM | 31.50’’X47.24’’
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers
Kegs per layer
Kegs per pallet
Height
Stacking in storage
Stacking for transport
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

pag. 12
POLYKEG® PRO LOGISTICS DATA SHEETS
SECTION 4
FILLED KEGS PALLETIZATION
PALLET 100X120 CM | 31.50’’X47.24’’
Palletization
12 L 406 oz. 16 L 541 oz. 20 L 676 oz. 24 L 811 oz. 30 L 1014 oz.
Layers
Kegs per layer
Kegs per pallet
Height
Stacking in storage
Stacking for transport
3+3 2+2 2+2 2+2 2+2
3+2 2+2 2+1 2+1 2+1
Layers
Layers
3*
20
60
2*
20
40
2*
20
40
2*
16
32
2*
12
24
1307 mm 51,45” 1098 mm 43,22” 1274 mm 50,15” 1268 mm 49,92” 1268 mm 49,92”
Wooden interlayer
120 cm 120 cm
97 cm
1,5 cm
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

pag. 13
POLYKEG® PRO LOGISTICS DATA SHEETS
SECTION 4
LOADING RECOMMENDATIONS
PALLET 100X120 CM | 31.50’’X47.24’’
PALLET 100X120 CM | 31.50’’X47.24’’
pallet plan view
CTR 20 ft Standard
CTR 40 ft High Cube
CTR 45 ft High Cube
Truck 13,6 mt
pallet plan view
CTR 20 ft Standard
CTR 40 ft High Cube
CTR 45 ft High Cube
Truck 13,6 mt
11
24
32
32
10
22
26
26
WARNINGS
When transporting filled kegs, it is recommended to use refrigerated containers.
When using refrigerated containers, the number of pallets may vary.
When stacking pallets, the load must be evenly distributed by using a rigid interlayer or an overturned pallet between one pallet and another.
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 must take into account the mechanical properties of the keg as reported on the technical data sheet, the local
regulations, and the means and manner of handling and transport, as well as the conditions of the storage areas.
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
SANITIZING
INSTRUCTIONS
SECTION 5

pag. 15
Before starting the filling, sanitize the manual filling kit (tubes, valves, seals, couplers, etc.) or the
automatic/semi-automatic filling 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: do not use any substance not specified in this manual.
SANITIZING INSTRUCTIONS SECTION 5
WHAT NEEDS TO BE SANITIZED
MANUAL FILLING KIT AND VALVE SANITIZATION
Hydroalcoholic solution in demineralized water
SANITIZING THE POLYKEG MANUAL FILLING KIT
70% MIN TIME
45 SECONDS
Soak the disassembled components of the manual
filling kit in the sanitizing solution listed above.
Please follow the dilution rates and time limits
indicated above. Rinse thoroughly and dry with
sterile air.
SANITIZING OF THE COUPLER AND THE
EXTERNAL PART OF THE VALVE
Clean and spray the external surface of the
components with the sanitizing solution listed
above. Please follow the above dilution rates and
time limits.
SANITIZING WITH AUTOMATIC AND SEMI-AUTOMATIC MACHINES
Hot water
AUTOMATIC/SEMI-AUTOMATIC MACHINE
SANITIZING
Maximum pressure
on the valve
0,8 BAR
Maximum temperature
85°C
Maximum time
5 sec.
Steam
Before starting the filling sanitize the
automatic/semi-automatic filler according to the
manufacturer's instructions.
SANITIZING THE EXTERNAL PART OF THE VALVE
Set the filler to sanitize the external surface of the
keg valve with hot water or steam according to the
above mentioned pressure, temperature and time
limits.
OR
Maximum pressure
on the valve
0,8 BAR
Maximum temperature
100°C
Maximum time
3 sec.
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

LIGHT AND STRONG
FILLING INSTRUCTIONS WITH
POLYKEG®MANUAL KIT
SECTION 6
POLYKEG PRO WITH BAG

pag. 17
FILLING INSTRUCTIONS WITH POLYKEG®
MANUAL KIT POLYKEG PRO WITH BAG
POLYKEG MANUAL FILLING KIT:
SECTION 6
Before filling, please refer to the warnings in the “Section 1” of the PolyKeg PRO
instruction manual and to the keg technical data sheets.
Fig. 1
PRESSURE TOPUP CONNECTION
PRESSURE GAUGE
GAS REGULATOR CONNECTION
PRODUCT FILLING VALVE
PRESSURE TOPUP GAUGE
PRODUCT FILLING CONNECTION
PRODUCT TUBE
COUNTERPRESSURE REGULATOR
KEG COUPLER MICRCO MATIC IS RECOMMENDED
GAS TUBE
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

Disassemble the PolyKeg® filling
kit and sanitize the components as
indicated in the “Sanitizing
Instructions” section.
Reassemble the kit properly and
close all valves.
Check that the pressures of the
filling system are correctly set and
below the maximum value
indicated. (3.5 bar/50 psi).
pag. 18
PREPARATION
1. Sanitizing 2. Assembly 3. Gas and product pressure
check
SECTION 6
CO 2
N2
MAX 3,5 BAR
MAX 50 PSI
Connect the product and gas
tubes to the filling kit.
K-VALVE ONLY
Connect the product and gas
tubes to the filling kit. Open the
red valve.
Work with the product valve to
remove any residual gas from the
product tube. Close the product
valve.
4. Gas and product tube
connection
5. Gas and product tubes
connection with K-valve
6. Product tube purging
FIG. 1 FIG. 2 FIG. 3
FIG. 4 FIG. 5 FIG. 6
FILLING INSTRUCTIONS WITH POLYKEG®
MANUAL KIT POLYKEG PRO WITH BAG
Before filling, please refer to the warnings in the “Section 1” of the
PolyKeg PRO instruction manual and to the keg technical data sheets.
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

Before filling, sanitize the parts in
contact with the product as
indicated in the “Sanitizing
instructions” section.
Make sure the filling head is properly connected to the valve, lower the
lever and check the internal pressure of the keg.
pag. 19
FILLING
7. Sanitizing 8. Connection and Counter-pressure check
SECTION 6
Work with the gas valve until the
desired counter pressure is
reached (approx. 0.5 bar lower than
the product filling pressure).
Open the product valve to start
filling and work with the
counterpressure regulator to set
and/or change the filling speed.
Once the nominal filling volume is
reached, close the product valve.
Do not exceed the nominal filling
volume to prevent the product
from leaking out of the bag.
9. Counter-pressure
regulation
10. Filling 11. End of filling
FIG. 8.3 - VALVE G-KFIG. 8.2 - VALVE S-DFIG. 8.1 - VALVE A-M
FIG. 9
FIG. 7
FIG. 10 FIG. 11
1,5 BAR
FILLING INSTRUCTIONS WITH POLYKEG®
MANUAL KIT POLYKEG PRO WITH BAG
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023

Close the regulator and work
on the gas valve to increase the
counter-pressure to a value
slightly higher than the product
filling value.
Quickly lift the lever and disconnect the coupler from the keg.
pag. 20
12. Pressure balance 13. Uncoupling
SECTION 6
FIG. 8.3 - VALVE G-KFIG. 8.2 - VALVE S-DFIG. 8.1 - VALVEA-M
FIG. 12
14. Valve sanitizing 15. Seal application
Remove any residual product with
water, sanitize the external part of
the valve as indicated in the
“Sanitizing instructions” section
and dry same.
Apply the seal.
FIG. 14 FIG. 15
FILLING INSTRUCTIONS WITH POLYKEG®
MANUAL KIT POLYKEG PRO WITH BAG
INSTRUCTION MANUAL
PolyKeg® Srl Via L. Da Vinci, 5/9 24064 Grumello del Monte (BG) – Italy T [phone] - [e-mail] - www.polykeg.com
This document is property of PolyKeg® S.r.l. - Unauthorized copying and use is strictly forbidden MI01 Rev. 13 dated 30/01/2023