CF80 Twin Head Micro Cask Filler

This unit is the second level cask filler in the Microdat range it meets the needs of the larger microbrewer that require high output or functionality than the Basic Cask Filler.
It delivers automatic cask filling (meter filling).
It will reduce beer losses to an absolute minimum.
It will provide a consistent black fill from an empty or full vessel. (No Fobbing)
It will fill in a reliable consistent time.
It will reduce bending and back strain for the operator.
It will reliably inject additions such as priming’s and finings.
It will reduce racking time.
It provides options for blending of beer or additions

The CF80 Twin Head Micro Cask Filler is...

Fully hygienic in design with food grade hoses and 304 stainless steel construction, with 316 SS wetted parts.
Simple to operate, clean and maintain
Fills two cask sizes as standard (normally 9 & 18 gallon)
4.5, 10,11,22,36,54 gallon as options
Will deliver 70 to 80 metered full firkins per hour
Self-cleaning
Upgradable to 120 firkins per hour and more

The Microdat Cask Filler Range

The whole Microdat cask filler range has been designed around the original and very successful Black Sheep 5 head automatic cask filler, which is capable of 60 firkins per hour per head. The key feature of the Microdat cask filler is the pump units, which deliver the consistent black (fob free fill). The same pump unit is used on the semi automatic basic cask filler and all fillers up to the fully automatic Black Sheep type filler. Apart from the typical hose, tube and butterfly valve used by most micro brewers the alternatives for filling have generally been either the traditional Briggs Jack Back and racking cocks or a counter pressure racker. The Microdat filler uses the unique properties of the Microdat Hygienic Hose Pump (peristaltic) or Hygienic Metering Pump.

The Twin Head HMP Pump Set

The Microdat Hygienic Metering Pump is the key to all cask fillers in the Microdat range excluding the Basic entry-level cask filler. It differs from the Basic pump set only via the addition off a digital feed back encoder fitted to the drive motor unit so it is possible to upgrade the HHP to a HMP in the future if required.

The main variation for the THMCF is the twin head arrangement, improved controls, automation and the ability to add additional options such as automated blending etc

The main pump controller in the HMP pump unit is a low cost, high functionality Lenze digital drive. The advances made to digital drives over the last few years have made the HMP a practical and economical option to deliver automated, non-sealed cask filling. By meter filling the cask up to the brim via the special HMP it is practical to fill each cask in a reliable realistic time without having have a mechanical structure to hold and seal the cask. The digital drive with closed loop encoder feed back means that the pump can be controlled to degrees of a rev to deliver accurate metering. The HMP still has the full benefits of an HHP set yet meters as well. These special drives enables each pump to be slowly ramped up to a set filling speed to give the perfect black fill and correct volume of additions. The drive unit also provides the additional speed for cleaning the filler etc when in CIP mode.

Beer Flow Control

Beer as we all know is a unique fluid in that you cannot control the flow rate of beer via a valve or orifice. If you reduce the flow rate through a valve or orifice you will increase its velocity and the dissolved gas breaks out to produce fob. Great on top of a Yorkshire pint but not so good when filling a cask or keg.

The traditional brewery methods of controlling beer flow when filling are the slow flow constant head vessel ie the Briggs Jack Back Racking Tank (the long horizontal vessel) combined with a Briggs racking cock. The almost constant head gives a consistent flow but the filling rate is slow and beer losses can be high. The cost of a Briggs Jack Back vessel and a set of racking cocks would also be very high and they are not easily cleaned by CIP.

The counter pressure filler is common to both cask and keg and uses a gas to control the beer flow. The original Black Sheep 5 head and Moorhouses twin head filler was designed for counter pressure filling, however the success of the HMP pump unit removed the need for counter pressure gas injection to control beer flow.

In keg filling the counter pressure gas can be 2 bar of CO2, in cask beer the counter-pressure gas is much lower as you would blow out the keystone, usually around 1 bar.

To control the beer flow into the cask or keg the gas is released, lowering the pressure thus allowing the beer to flow. The problem for counter pressure systems is the gas is very expensive, the filler has to seal the cask and is thus expensive; also releasing 2 bar CO2 from a keg to atmosphere for each fill is not exactly very green.

The Microdat pumped fill system uses a positive displacement hose (peristaltic) type pump, with a food grade hose liner, the pump is simple and very hygienic, the squashed and sealed tube acts like a moving cylinder around the hose, for a two roller pump you get two chambers of fluid for each revolution. With no revs you get no flow, the higher the speed the faster the flow. The head of beer feeding the pump has little effect on the pumps output and the gentle low shear action of the hose pump treats the beer nice and gently. The unique design of the Microdat new hose pump sets also includes a special pulsation damper, which soften the pumps pulses to give a very smooth and gentle beer flow. The only need for a gas when filling with a Microdat cask or keg filler is to blanket and protect the beer from O2 during filling however there is always some initial gas break out (CO2) during the initial first few seconds of filling and this is usually sufficient to provide a blanket between the beer and the escaping O2 from the cask via the vent.

The CF80 Twin Head Micro Cask Filler

This second level system is designed for the growing, quality micro cask brewer who needs a high quality consistent fill at a reasonable production rate of 70 to 80 Firkins per hour (less for Kilderkins). The meter fill enables the whole filling process to be automated allowing a slick changeover from filling one cask to the next cask via the HMP pump set. To achieve maximum output from the pump set, twin filler heads are built into the filler so that operator simply places the casks, inserts the head and presses the fillers go button the controls do the rest. After filling the operator simply removes the head, closes the cask and ejects it, then replaces it with the next washed and keystoned empty cask. The actual filler head on the twin micro filler has automated beer divert valves and an automated beer head inlet valve both pneumatically operated. This beer control system is identical to the higher performance twin head 120 firkins per hour cask filler as installed at Moorhouses brewery and will thus reduce potential beer losses from operator error to an absolute minimum. The tight beer control and meter fill system also reduces operational beer losses an absolute minimum loosing only a few drips from the empty and vented beer tube. The meter filling system also makes beer blending at the filler a real practical option ie mixing beer feed stocks to ratios such as 1/3 plus 2/3rds or ½ and ½, this can also apply to the additions ie mixing finings, priming’s and adjunct in set recipes is all possible with the Twin Head Micro Filler.

This twin head filler uses automatic controls to divert the beer and additions to either of the two filling stations rather than transferring the filling tube between stations, as is the case on the basic filler. This enables the operator to set up each cask and allow the system to meter fill each cask in turn as the pump set becomes available.

The higher level of automation on the Twin Head Micro Filler is accompanied with a range of operator interface screens (HMI’s) there are various alternative touch screens from the simple monochrome to a full colour screen which allows the operator to set the system up for its specific production requirements. Also within the touch screen is the functionality for calibrating the pumps, which for the beer pumps is set in degrees of rotation of the pump, giving a very fine adjustment to volume of beer delivered.

Operating the CF80 Twin Head Micro Cask Filler

Having set up the cask size via the touch screen and the recipe if the blending option is included the operator simply places the washed and keystoned cask on the station, presenting the shive hole uppermost. The operator simply inserts the filler head into the cask and then presses the start button located on the head. If the pump set is primed and ready it will begin its filling sequence. The relevant beer divert valve will open along with the valve in the filling head, the main beer pump will then begin to ramp up to speed very slowly at first allowing the open ports in the beer tube to be covered before the pump attains full speed and full flow. As the pump attains full speed the additions pump will begin operation injecting the pre-set amount of additions i.e. finings, priming’s adjunct etc. Please note that as standard on the Twin Head Filler system a finings senor is included to detect the presents of finings, if finings injection is included in the recipe for the filling operation the finings sensor must remain active ie covered with finings at all times during in filling. If the sensor fails filling will stop, the screen will shown an alarm condition “Finings Supply Failed”. If options such as blending are included then additional supply sensors should be added to ensure that the supply is always available on demand.

When the cask is nearing full the additions pump will have stopped and the main beer pump will begin to slow down to deliver the final fill level into the cask. When the cask is full the pump will stop and when stopped the beer valve into the head will close along with the beer divert valve. The head will then be raised from the cask by a pneumatic cylinder pulling up the heads support wire rope.

If the next cask is set filling will commence on the next head.

The operator will now have free access to inspect and close the cask and eject it via the foot pedal and then set up the next cask.

The whole operation is simple but effective it removes the tedium off having to watch each cask fill and removes the possibility of operator error resulting in beer losses.

Cleaning CIP

The Twin Head Cask Filler uses the pump set and its control system to clean filler unit by circulating cleaning fluids though the pumps and heads etc using the control system and auto valves to route the cleaning fluids. On the twin head filler a filling head CIP manifold is included this links up the filling heads to a common return via a hose connection. On the pump set a common CIP inlet header is supplied which links all the pump inlets routes to a common inlet hose connection, for blending options additional connections will be necessary on the CIP Inlet manifold. To clean the plant a process of circulating, Pre-rinse liquor, cleaning fluid and finally Post-rinse liquor is recommended. The filler CIP can be undertaken as part of the beer supply vessels cleaning routine or undertaken as a separate exercise. As a separate system three tanks such as transit tanks could be used. The first Pre-rinse tank could be reclaimed Post rinse liquor from the last clean. The 2nd tank could be could be retained cleaning fluid possibly used a few times prior to discharge. The 3^rd tank would be a clean cold liquor supply tank, which would supply the Post-rinse liquor. The normal connections for CIP is to use the main beer supply hose for the CIP supply to the pump set and an additional hose is normally required to return the CIP fluids back to the appropriate CIP tank from the filling heads CIP manifold.

Microdat would generally recommend hygienic clamp type fittings for all peristaltic pumped hose connections, as these are not prone to loosening and thus potential CIP fluid leaks.

Options For The Twin Head Filler

As the twin head filler has a powerful processor and touch screen to control and manage the filling plant many options are available, please note the list of options below is common items should you have a specific need please feel free to talk to Microdat about other possible options.

Optional Extras

2m 1.5 inch bore beer supply hose with hygienic connections each end
3m 1.5 inch bore beer supply hose with hygienic connections each end
4m 1.5 inch bore beer supply hose with hygienic connections each end
6m 2.0 inch bore beer supply hose with hygienic connections each end

2m ½ inch bore additions supply hose with hygienic connections each end
3m ½ inch bore additions supply hose with hygienic connections each end
3m ½ inch bore additions supply hose with hygienic connections each end
3m ½ inch bore additions supply hose with hygienic connections each end

2m 1.5inch bore CIP return hose and hygienic connections each end
3m 1.5inch bore CIP return hose and hygienic connections each end
4m 1.5inch bore CIP return hose and hygienic connections each end
6m 1.5inch bore CIP return hose and hygienic connections each end

Additional length on request
Additional cask size filling for each additional cask size the unit will have additional control software, extra touch screen software for recipe selections and an appropriate length beer tube.
Beer Blending For two beer sources we would add two extra auto valves on the main beer pump inlet, we would also recommend the fitting of beer sensors on each inlet connection. We would also provide beer blending software and recipe selection via the touch screen. The CIP Inlet Manifold would be modified to suit
Additions Blending For two additions sources we would add two extra auto valves on the additions pump inlet, we would also recommend the fitting of beer sensors on each inlet connection. We would also provide beer blending software and recipe selection via the touch screen. The CIP Inlet manifold would be modified to suit.
Colour Touch Screen To replaces the standard mono screen
Remote Access & Diagnostics Either via a modem or existing Internet access so Microdat can open remote access to your plant and remotely diagnose problems or make recipe amendments etc.
Cask Filling & Ejector Stations (normally sold as a pair)
Delivery to site (excluding off loading)
On site commissioning and operator training
Hard Copy operational and maintenance manuals
1 set recommended spares
Low noise air compressor to meet the demand of the above plant
Castors to replace the fixed levelling feet.

Services Required

Mains electrical supply 240v 50Hz single-phase 16A

Compressed air supply 5 bar minimum industrial quality compressed air

Rated at 800 l/min

Beer Supply Min via 1.5-inch hose up to 4m

2.0 inch over 4m

Min Head 0m

Max Head 8m

Outside these parameters please consult Microdat

CIP Supply Pre-rinse liquor

CIP Cleaning Fluid

Post Rinse Water (This may be returned for Pre-Rinse)