The KHS Group has further developed the sequential overhaul of filling valves, also known as rolling maintenance, to shorten maintenance windows and increase line availability. The principle avoids a full shutdown for a complete overhaul and instead removes, at planned intervals, only as many valves as are in a replacement set, typically around 20. Depending on container category and machine type, KHS fillers average about 125 valves. In a conventional overhaul, two employees need up to two weeks to refurbish all valves. With the sequential approach, one complete set can be exchanged in about two hours, after which the filler can be returned to operation. The removed valves are overhauled and leak tested on a mobile station before reinstallation, which reduces the error rate at startup to under 1%. As a result, downtime falls from roughly two weeks to about 10 hours. "It significantly reduces downtime and ensures that production can start again more quickly and with quality that has been tested," summarizes Torben Brill, service product manager at KHS GmbH. The approach enables beverage bottlers to work more flexibly and increase the long-term availability of their systems.
HMI and test kit upgrades
To make the process more efficient and flexible for beverage bottlers, KHS has improved the supporting technology. An advanced HMI lets users choose between different test procedures, and a new adapter plate decouples the filling valve from the base plate. As a result, a single test kit can be used for different types of filling valve, which is beneficial for sites operating several filler types. For customers, this reduces the amount of equipment required, shortens maintenance cycles, and provides valve quality that has been verified before installation.
A new adapter plate decouples the filling valve from the base plate.
Torben Brill said, "KHS is continuously developing its products further, always taking specific customer requirements into account." He added, "We think it’s important to not only provide our customers with a technical upgrade, but also to make their day-to-day production work noticeably easier."
Further development of the sequential overhaul of filling valves means a single test kit can be used for different types of filling valve – a major benefit for production sites with several types of filler.
On-site service package
KHS brings the workshop directly to the customer with a mobile overhaul and test station, enabling all work to be carried out on site. Customers can perform the process themselves or assign it to KHS personnel. The package contains everything needed for one year, from measuring devices and an automatic testing device through spare and wear parts to sealing rings and easy-to-understand installation and operating instructions. The service is available as part of a multi-year contract, with the test kit provided on loan free of charge. Before each assignment, KHS checks whether the customer’s filling valves are suitable for the process to ensure proper application.
