In the beer filling and packaging process, there are many factors that affect the quality of the final finished product. Among them, whether the equipment operates normally is not only related to improving production efficiency, but also more related to whether product quality is stably up to standard.

Based on many years of practical experience, the author summarizes and analyzes various equipment failures that affect product quality, and lists some preventive measures for exchange with peers.

1 Fault Analysis and Handling of the Bottle Washer

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Washing solution temperature fails to meet requirements	More “fat bottles” (bottle swelling)	1) Adjust steam pressure. 2) Check whether the steam trap is blocked. 3) Check whether the heater is intact. 4) Check whether the valve cores of the steam valve and diaphragm valve have fallen off.	Identify problems and contact maintenance personnel in time.
2. Nozzles are clogged or poorly aligned	Dirty bottles (inside)	1) Label-removal mesh belt damaged. 2) Transmission parts of the spray pipe are worn or damaged. 3) Incomplete washing. 4) Circulating water is too dirty.	1) Maintenance staff patrol >4 times per day. 2) Thorough cleaning; establish cleaning standards. 3) Perform according to cleaning standards.
3. Running speed too fast; soaking time insufficient	More “fat bottles”	Adjust running speed and bottle-washing process according to bottle source.	1) Communicate in advance with bottle supplier according to production tasks. 2) Adjust running speed and washing process in time based on bottle source.
4. Low pump pressure	Dirty bottles	1) Clear pipelines or filters. 2) Check whether water level is normal. 3) Check whether pipelines have leakage. 4) Check whether impeller is intact and normal. 5) Check whether the pump rotation direction is correct.	1) Operate according to process requirements. 2) Check water level >3 times per shift. 3) Check pump pressure gauge >5 times per shift.
5. Long bottle retention time inside the machine	“White bottles” appear	Pick out and handle separately.	1) Cool down in time. 2) Stop infeed; check the sections where white bottles are prone to occur at the outfeed.

2 Fault Analysis and Handling of the Filling & Capping Machine

(1) Fault Analysis and Handling Affecting Vacuuming

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Vacuum pump vacuum degree is low	Poor vacuum effect	1) Check whether the vacuum pump head is worn. 2) Check whether the incoming water meets requirements.	Inspect once every 30 minutes.
2. Vacuum valve stem wear is severe	Poor air displacement in bottle	Repair or replace valve stem.	Check once per month.

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
3. Vacuum valve stem sealing gasket is swollen or damaged	Poor air displacement in bottle	Check and replace swollen/damaged sealing gasket.	1) Inspect once every 15 days during production. 2) Replace once per year.
4. Vacuum line leakage	Vacuum degree decreases	Tighten or replace vacuum line sealing gasket.	Check connection points once per month.
5. Vacuum slide rail wear is severe	Poor air displacement in bottle	Replace vacuum slide rail.	Check once per month.
6. Vacuum cylinder is not flexible and cannot extend/retract	Poor air displacement in bottle	1) Check piston sealing gasket in the cylinder. 2) Check air source pressure. 3) Check whether piston rod is deformed.	1) Inspect once every 15 days during production for air leakage. 2) Pre-shift inspection.
7. Beer tank is not level	Valve stem insertion is offset	Adjust the support frame to the same level.	Confirm once every 3 months during production.
8. Air exists in beer	Dissolved oxygen is unstable	Exhaust air inside the polishing filter.	Exhaust air during filling.
9. Abnormal structure of valve seat / pressure relief valve seat / vacuum valve seat	Poor sealing	Check the fit between valve seat and valve.	Use spare parts of the same specification/model.
10. Cleaning valve or cleaning pipeline leaks air	Quality decreases	Replace sealing gasket or leaking valve.	Check leakage status at each point once per month.
11. Central device leaks air or cross-leaks	O₂ purity decreases; dissolved oxygen unstable	1) Replace sealing gasket of the central device. 2) Remove grease nipple.	Inspect once every 7 days during production.
12. Poor contact between vacuum slide rail and vacuum valve stem; abnormal wear	Poor air displacement in bottle	Adjust slide rail or slide rail clearance.	Inspect once every 7 days during production.
13. “No bottle, no vacuum” valve stem falls off	Unable to vacuum	Replace valve stem.	Inspect once every 7 days during production.
14. Fixing bolts of vacuum device loosen	Dissolved oxygen unstable or unable to vacuum	Fix/secure vacuum device.	Inspect once every 7 days during production.
15. Fixing bolts of intake control module loosen	Dissolved oxygen unstable or unable to vacuum	Fix/secure vacuum device.	Inspect once every 7 days during production.

(2) Fault Analysis and Handling Affecting Bottle-Neck Air Content

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Outlet pressure is unstable	Bottle-neck air is unstable	Check high-pressure pump piston or sealing parts.	Check once per year.
2. Pressure regulating valve fails	Bottle-neck air is unstable	Check pressure regulating valve fixing bolts or fixing sleeve.	1) Check once per shift. 2) Communicate with maintenance in time.
3. Pipeline leakage	Water pressure unstable or no water pressure	Repair leakage point.	Patrol in time after start-up.
4. Nozzle insert outlet deformed	Mist appears	Replace nozzle insert.	Inspect in time during production.
5. Less foam overflow	Bottle-neck air is unstable	1) Adjust nozzle angle. 2) Adjust beer level.	1) Adjust in time during production. 2) Replace with a suitable return gas pipe.

(3) Fault Analysis and Handling Affecting Capping Performance

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Capping machine height is incorrect	Bottle breaks; high leakage rate	Readjust height to 86 ± 1 mm.	Check once per year.
2. Middle star wheel / outlet star wheel / capping star wheel are not synchronized	Cap pressed off-center or bottles crushed	1) Tension or replace the sleeve roller chain driving the capper. 2) Readjust the star wheels.	Check once per week.

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
3. Bottle-support pad on bottle-holder seat is worn	Bottle unstable; crushed or cap pressed off-center	Replace bottle-support pad and spacer ring.	1) Check once per month. 2) Replace once per year.
4. Capping mold is incorrect	Damaged bottle mouth; high defect rate	Install the correct capping mold.	Strict inspection control.
5. Capping is too tight or cannot spring back	Bottle mouth crushed	1) Replace capping spring. 2) Tighten punch limit nut.	Check once per year.
6. Middle star wheel position deviates	Bottle crushed or nonconforming products produced	Readjust positions of the middle star wheel and capping star wheel.	1) Communicate with operators daily. 2) Check once per week.
7. Capping star wheel position incorrect or severely worn	Cap pressed off-center or bottle broken	Adjust or replace capping star wheel.	Check once per month.
8. Cap-pass device severely worn or pressure spring damaged	Bottle crushed or cap pressed off-center	Replace cap-pass device or spring.	1) Communicate with operators daily. 2) Check once per year.
9. Cap pick-up device has no magnetism or weak magnetism	Cap centering is poor	Replace cap pick-up device.	1) Communicate with operators daily. 2) Check once per year.

3 Fault Analysis and Handling of the Pasteurizer (Sterilizer)

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Water leaks at flange joints; rubber press-in joint disengaged or leaks	Flow decreases; prone to under-pasteurization	1) Tighten bolts at each connection. 2) Replace flange connection parts. 3) Install or replace press-in joint.	Communicate with operators; execute according to maintenance standards.
2. Pump pressure unstable	1) Poor pasteurization effect 2) Mechanical seal damaged	1) Check water tank level so pump pressure reaches specified value. 2) Clean inlet filter pipe. 3) Replace pasteurization water; remove contaminants.	1) Check water level and water-shortage protection device at any time. 2) Change water according to cleaning standards.
3. Pump reversed or impeller clogged	Flow decreases; prone to under-pasteurization	1) Swap power supply wiring. 2) Remove impeller blockage.	1) Test run after installation. 2) Ensure filter screen is installed in place after cleaning.
4. Grating seat loosened/deformed/fallen off	PU value too high	Tighten grating seat; repair gratings.	1) Communicate with operators. 2) Check once per year.
5. High-temperature zone temperature too high	PU value too high	1) Check diaphragm valve pressure. 2) Repair automatic-control diaphragm valve.	Operators strengthen responsibility and patrol.
6. Running time too long	PU value too high	Check step-move time, transmission parts, connection points.	1) Communicate with operators. 2) Patrol each shift.
7. Condensate cannot be discharged	Temperature low; prone to under-pasteurization	1) Check whether steam trap and condensate lines are blocked; clear them. 2) Temporarily open bypass valve.	1) Communicate with operators. 2) Discharge condensate in advance.
8. Temperature control system not properly adjusted	Temperature unstable; prone to under-pasteurization	1) Check whether instrument line joints leak air; adjust. 2) Calibrate instrument temperature values.	Communicate and replace in time.

4 Fault Analysis and Handling of the Labeling Machine

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Gripper finger releases too early or too late	Label misaligned or label drops	Adjust the gripper release cam plate so the gripper releases earlier or later.	1) Check before start-up each shift. 2) Check fixing bolts once per week.
2. Gripper finger deviates from neck-label sponge cam lobe	Label misaligned	Adjust timing between gripper release and neck-label sponge cam lobe.	Check before start-up each shift.

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
3. Label box position deviates	Label tilted	Adjust label box height; move label up/down or left/right.	Check and adjust before production each shift.
4. Brush fixing bolts loosen; bristles too short	Label edge lifts	Tighten fixing bolts; replace worn brush.	Check before production.
5. Brush deformed	Poor brushing effect	1) Clean label glue on the brush. 2) Replace brush.	1) Clean daily. 2) Purchase good-quality brushes.

5 Fault Analysis and Handling of the Shrink-Wrapping Machine (Plastic Packaging

Main Cause	Resulting Outcome	Handling Method	Preventive Measures
1. Upper paper chain is too forward or too backward	Affects packaging quality	Adjust synchronous belt pulley.	Communicate and patrol each shift.
2. Film length and tension are improper	Wrap is loose	Adjust film length and tension to make film expand.	Inspect and adjust during production.
3. Bridge plate is uneven	Shaking occurs; package becomes loose	Repair or replace bridge plate.	1) Detailed inspection before production. 2) Communicate and patrol each shift.
4. Wrapping belt is not synchronized with output belt	Wrap is loose	1) Check whether belt pressing rubber roller is loose. 2) Check pressing spring of the rubber roller.	Communicate and patrol each shift.
5. Air volume too small	Wrap is loose	1) Open blower and check whether impeller is deformed. 2) Check whether air duct leaks.	1) Communicate and inspect each shift. 2) Major overhaul once per year.
6. Air direction is not suitable	Wrap is loose	Adjust air direction.	Adjust according to actual conditions during production.
7. Oven insulation is poor	Wrap is loose	1) Check whether belt pressing rubber roller is loose. 2) Check pressing spring of the rubber roller.	Communicate and patrol each shift.

Summary

In summary, behind every quality problem, there may be potential equipment failure. This requires operators to strictly follow operating procedures, avoid over-temperature, over-pressure, over-speed and over-load operation, and conduct periodic inspections during operation. Detect problems and adjust in time, and do daily maintenance and scheduled maintenance. Only when equipment operates normally can it become a solid foundation for continuous improvement of product quality.

6 Inspection of Leakage Points in Filtration Equipment and Pipelines

The “running, emitting, dripping and leaking” in filtration equipment have a great impact on the dissolved oxygen of bright beer. After filtration starts, first check visible leakage points of the filtration system. Inspection should proceed from the equipment and pipelines between the fermenter outlet and the bright beer tank inlet. Afterwards, perform online dissolved oxygen testing near the bright beer tank. If dissolved oxygen shows regular high–low fluctuations, it indicates hidden leakage points in the filtration system and requires careful inspection (for example, when our company discovered that the online oxygen test of the high-concentration diluter only had an air leakage problem).

7 Impact of CO₂ Purity (Table 3)

CO₂ directly contacts beer during deaerated water preparation and high-concentration dilution, and its purity has a significant impact on bright beer dissolved oxygen. The CO₂ purity used for filtration should be ensured to be above 99.995%.

Table 3 Relationship Between CO₂ Purity and Online Dissolved Oxygen

CO₂ Purity (%)	99.975	99.980	99.990	99.995
Bright beer tank oxygen (ppb)	60	30	10	< 5

8 Bright Beer Stabilization Time

Reducing substances in beer will consume part of dissolved oxygen. When the bright beer tank uses CO₂ to maintain good head pressure, the dissolved oxygen in bright beer will gradually decrease as storage time extends, and basically reaches a stable state after 4 hours, as shown in Table 4.

Table 4 Relationship Between Bright Beer Stabilization Time and Oxygen Content

Stabilization time (min)	20	60	120	180	240	300	360
Bright beer oxygen content (ppb)	24	19	17	16	15	15	14

9 Establishment of a Management System

There are many factors affecting bright beer dissolved oxygen, and systematic tracking and inspection are required. For example, when a fermentation tank is opened and after each precoat on the filter, before beer enters the bright beer tank, the dissolved oxygen of beer, the oxygen content of deaerated water, and CO₂ purity should be measured; during the process, check once per shift and establish corresponding records, linking them to operator responsibilities.

Reducing bright beer dissolved oxygen is a meticulous operation process. Each company can formulate improvement measures based on actual conditions and give full play to the participation and cooperation of operators. In our company, over two months, bright beer dissolved oxygen stabilized from an average of 35 ppb to below 6 ppb.

References

Tian, J. (2013). Impact of packaging equipment failures on beer quality control. BeerTech (Technology Exchange), (09), 51–53. (Total Issue 189).