KHS has redesigned its Innokeg Contikeg and Innokeg Combikeg keg washing and racking systems, with updates focused on line availability, operation, spare parts supply, hygiene, safety, cybersecurity and resource efficiency.
The fully automatic Innokeg Contikeg washes and racks up to 1200 kegs per hour using a continuous carousel process. During operation, kegs pass through all production stages without being decoupled, enabling a continuous production sequence. The system handles containers from five to around 58 litres for products including beer, mixed beer beverages, whiskey soda, wine, water, soft drinks and juice.
The system uses KHS' Direct Flow Control (DFC) filling technology, which regulates the filling flow rate through a valve rather than increasing CO₂ pressure in the keg. According to KHS, this reduces CO2 consumption by up to 40 per cent while enabling controlled, foam-free filling.
The redesign also introduces a new valve manifold, already used elsewhere in the company's filling technology portfolio, replacing the previous L-shaped media transfer system. KHS says standardising the component across different equipment simplifies operation and maintenance while improving the availability of spare parts.
Stefan Schuhriemen, head of the KHS Keg Technology Product Centre, said the integrated central distributor also contributes to process stability.
"This controls the media feed from a central point, thus reducing the number of individual valve switches needed in the core process. In turn, this then lowers system complexity, minimises wear and at the same time enhances process stability."
The updated Innokeg Contikeg operates through KHS's ClearLine HMI operator panel, which identifies faults to simplify troubleshooting. A revised messaging system allows the machine to continue operating if a fault occurs on a single racking head by automatically shutting down only the affected head, while production continues. KHS says this differs from linear machines, where a single station failure can stop the entire process.
The redesign also incorporates IO-Link technology, enabling the system to identify failed sensors and automatically transfer parameters to replacement components once they have been installed, reducing downtime.
KHS has also updated the hygienic design of the machine, including simplifying the wiring layout through the new valve manifold. The washing system uses pulsating sprays with up to three chemical cleaning media and includes a soaking function for fittings and spring assemblies.
Schuhriemen said, "We paid strict attention to all aspects of hygiene when redesigning our kegging system. Among other things, we've simplified wiring by integrating a new valve manifold and thus eliminated possible risks to hygiene here. Hygienic line design is especially critical when processing sensitive beverages such as low- and no-alcohol or NoLo beers, as these make extremely high demands of microbiological safety."
The redesign also includes revised safety switches, improved CO2 extraction and new protective housings.
The redesigned Innokeg Contikeg complies with DIN EN 415-2:2025 and is designed to meet the requirements of Regulation (EU) 2023/1230 on machinery, which takes effect in January 2027, as well as the EU Cyber Resilience Act.
Schuhriemen said compliance with EU standards is required for CE marking.
"As a machine and systems manufacturer, we're obliged to provide proof of the conformity of our products with valid EU standards and regulations. This forms the basis of the CE mark and goods entry on the European market."
The redesigned Innokeg Combikeg has also been updated to meet the forthcoming EU machinery regulation and the EU Cyber Resilience Act. Designed for lower-capacity operations, it combines the entire keg washing and racking line in a single compact machine that fits into one shipping container, allowing it to be integrated where space is limited.
