Krones spare parts Beverage Production Line Maintenance & Overhaul Standard Procedure
Krones Beverage Production Line Maintenance & Overhaul Standard Procedure
The whole process strictly follows five golden rules: LOTO lockout-tagout, genuine Krones spare parts, torque standard, lubrication specification, and hygienic validation.
Machine Shutdown & LOTO Lockout
Cut off power, compressed air, steam and material supply; hang warning signs and lock main power switches; release residual pressure and stored energy of the system.
Hygienic Isolation
Isolate hygienic zones including Filler, UHT and CIP system independently to avoid cross-contamination.
Tools & Spare Parts Management
Adopt Krones special tools only; use original genuine Krones spare parts exclusively, never substitute with non-OEM replacements.
2. Daily Maintenance (Per Shift / Daily, Operator In Charge)
Pre-Start Preparation (10–15 Minutes)
Cleaning: Wipe machine surface, star wheels, gripper plates, filling valves, discharge outlets, conveyor belts and safety guards; remove syrup stains, residue and dirt; disinfect hygienic areas with 75% alcohol.
Safety Inspection: Check emergency stop, safety doors and guards for intact condition; verify no leakage or damage in pneumatic circuit (0.6–0.8 MPa), water circuit and electric circuit; confirm normal status of CIP/SIP valves.
Lubrication: Apply 1–2 drops of Krones specified lubricating oil (e.g. ISO VG 220) to daily lubrication points including chains, guide rails, cylinder hinges and bearings; over-lubrication is strictly prohibited.
Jogging Test: Run idle for 1–3 minutes to check abnormal noise, vibration and jamming; ensure accurate positioning of filling, capping and labelling; verify sensitivity of sensors and photoelectric switches.
Online Operation Monitoring (Full-Time)
Process Parameters: Monitor air pressure, water pressure, temperature, flow rate, filling pressure/liquid level, capping torque, labelling accuracy and date coding clarity.
Abnormal Noise & Vibration: Check motors, gearboxes, bearings, gears and chains for abnormal sound and over-temperature (≤40℃).
Leakage Inspection: Ensure no dripping of material, water, steam or lubricant; keep perfect sealing in hygienic zones.
Post-Shutdown Maintenance
CIP Cleaning (Mandatory for Hygienic Lines)
Pre-rinse: Flush with clean water for 3–5 minutes to remove residue.
Alkaline cleaning: 1.5% NaOH at 85℃, circulate for 15–20 minutes to remove protein and grease.
Hot water rinse: Rinse with 85℃ hot water until neutral.
Acid cleaning: 0.5% HNO₃ at 60℃, circulate for 10–15 minutes to remove limescale.
Final rinse: Flush with sterile water until conductivity ≤5 μS/cm.
Surface Cleaning: Wipe the whole machine thoroughly, remove syrup and adhesive residue; keep conveyor belts and mesh belts clean and dry.
Drainage & Power Off: Drain residual water from pipelines, turn off water, air and power supply, restore LOTO safety lockout status.
3. Weekly Maintenance (Maintenance Team + Operator, 4–8 Hours)
Deep Cleaning & Disassembly
Disassemble and clean filling valves, capping heads, star wheels, gripper plates, guide rails, filters, nozzles, O-rings and sealing gaskets.
In hygienic area: Dismantle hygienic valves, distributors and CIP dummy cups for cleaning and sterilization; inspect sealing rings for aging and deformation.
Fastening & Adjustment
Re-tighten all bolts on machine frame, motors, gearboxes, star wheels and bearing housings per Krones standard torque values.
Adjust tension of belts and chains (oven chain, conveyor chain); inspect wear and elongation, re-tension or replace worn spare parts if necessary.
Calibrate gaps between filling valve & bottle mouth, capping head & bottle top, star wheel & gripper plate; correct synchronization and phase for blow molding-filling-labelling linkage.
Lubrication System Inspection
Check oil level, working pressure, filter element and pipeline leakage of centralized lubrication station; replace oil and filter elements per maintenance cycle.
Replenish high-temperature grease (e.g. Molykote) for key bearings and gears; check overheating and abnormal noise.
Electrical & Pneumatic Maintenance
Dust removal for electric cabinet, cool fan inspection and terminal fastening; insulation test (≥1 MΩ).
Drain water from pneumatic filters, calibrate pressure reducing valves, test solenoid valve action, adjust cylinder leakage and buffer damping.
4. Monthly / Quarterly Maintenance (Maintenance Team Led, 1–2 Days)
Comprehensive Equipment Inspection
Mechanical parts: Inspect spindle, bearings, gearboxes, couplings, cams and guide rails for wear, crack and deformation; disassemble for detailed inspection when needed.
Power system: Motor insulation, temperature rise and vibration check; inspect gearbox oil level and oil quality, replace gear oil every 5000 working hours.
Hydraulic & pneumatic system: Monitor pump station pressure and oil temperature, check leakage; calibrate accumulator pressure and replace filter elements.
Deep Hygienic System Maintenance
SIP sterilization validation: Verify steam temperature (≥121℃), pressure and holding time; test water leakage and level alarm of sterile water system.
Sealing renewal: Replace O-rings, gaskets and sealing components all over the line (especially hygienic zone) to prevent aging leakage.
Precision Calibration
Filling accuracy: Calibrate flow and liquid level sensors, control error within ≤±0.5%.
Capping torque: Calibrate capping head torque (e.g. 25–35 N·cm) to ensure leak-proof sealing.
Labelling & coding: Calibrate position, angle and printing clarity; adjust sensor sensitivity.
Wear Parts & Aging Spare Parts Replacement
Wear parts: Conveyor belts, mesh belts, rollers, guide plates, nozzles, filters, brushes, belts and chains.
Aging parts: Cables, hoses, sealing parts, solenoid valves, sensors and indicator lights.
5. Annual Overhaul & Spare Parts Replacement (Krones OEM or Certified Team, 3–7 Days)
Three Standard Overhaul Modes
On-Site Full Overhaul: Complete machine disassembly, deep cleaning, repair or replacement of core components (spindle, bearing, gearbox, hygienic valve block), precision restoration and hygienic validation.
Component Replacement Solution (Recommended for Minimum Downtime): Remove old modules on-site (filling module, labelling unit, CIP station), install pre-reconditioned original Krones refurbished assemblies plug-and-play; downtime ≤ 8 hours; send old components back to factory for overhaul and inventory storage.
Factory Return Overhaul: Send core units (ultra-clean filling head, UHT heat exchanger) back to Krones factory for full disassembly, precision cleaning, inspection, repair/ spare parts replacement, calibration, performance testing and quality certification before re-installation.
Standard 11-Step Overhaul Workflow
Planning & Approval: Confirm overhaul scope, schedule, risk assessment and solution; prepare Krones spare parts and special tools.
Shutdown & LOTO: Safety isolation and residual energy release.
Disassembly & Marking: Disassemble from outer to inner, accessory to main unit; number, photograph and classify all components.
Cleaning & Inspection: Remove oil and residue; detect wear, crack, deformation and seal failure; judge repair or replacement demand.
Repair & Spare Parts Replacement: Repair repairable components professionally; install genuine Krones spare parts and fasten per standard torque.
Assembly & Adjustment: Reassemble in reverse disassembly order; fill specified lubricant grease; calibrate gap, tension, stroke and electrical parameters.
No-Load Commissioning: Jog and low-speed operation to inspect abnormal noise, temperature rise, vibration and leakage.
Load Commissioning: Gradually run to rated speed; monitor pressure, current, temperature and precision for performance verification.
Hygienic Validation (Sterile Line): SIP sterilization test, sterile water microbiological inspection and hygienic zone tightness test.
Acceptance & Filing: Self-inspection → mutual inspection → professional inspection; fill overhaul records, sign off and clean site.
Production Resumption: Parameter backup, operator training and formal production restart.
6. Special Maintenance for Key Systems
1) CIP/SIP Hygienic System (Core Unit)
CIP: Mandatory after each production batch; strictly follow formula for alkaline/acid concentration, temperature and time; circulation flow ≥ 2 m/s; final rinse conductivity ≤5 μS/cm.
SIP: Execute daily before sterile production; steam ≥121℃, 0.2 MPa, holding 30 mins; sterile water tank liquid level ≥30% to avoid dry burning and alarm.
Filter Cartridge: Replace terminal 0.22 μm sterile filter every 3 months; pass filter integrity bubble point test.
2) Blowing Molding Machine (If Integrated)
Adjust heating chain tension and lubrication; inspect roller wear; calibrate oven temperature uniformity.
Test blowing valve leakage and pressure calibration; clean nozzles; adjust mold gap and alignment.
3) Labelling Machine
Clean glue roller and scraper, inspect wear and gap; control hot melt glue temperature at 160–180℃ and calibrate glue dosage.
Adjust label web tension and sensor sensitivity; calibrate labelling position; inspect slitting blade wear.
7. Fault Handling & Quick Recovery Process
Abnormality Reporting: Operator immediately stops machine once abnormal noise, leakage or precision deviation occurs, report to team leader and maintenance department.
Diagnosis & Evaluation: Maintenance engineer inspects on-site, combines HMI alarm, historical data and fault code to locate root cause (mechanical / electrical / hygienic).
Emergency Handling: Fix minor faults (sensor contamination, belt deviation) on-site directly; start overhaul or spare parts replacement plan for serious faults (bearing burnout, hygienic valve leakage).
Validation & Recovery: Complete no-load → load → hygienic test (if required) after repair; confirm normal parameters and zero leakage.
Record & Filing: Fill fault report including phenomenon, root cause, solution, used spare parts and working hours; update equipment file and analyze failure trend for preventive maintenance.
8. Core Management Guidelines
Follow OEM Specification: Strictly comply with Krones Operation & Maintenance Manual; never modify original parameters, torque values and lubrication points arbitrarily.
Spare Parts Inventory Strategy: Keep safety stock ≥ 2 sets for key Krones spare parts (filling valve, hygienic seal, sensor, solenoid valve); prioritize original OEM procurement.
Personnel Qualification: Maintenance and operation staff must complete Krones certified training and hold valid certificates; arrange regular re-training.
Data-Driven Management: Establish equipment ledger to record maintenance, overhaul, fault and parameter changes; adopt Krones KPI system to analyze OEE, failure rate and MTBF for continuous maintenance cycle optimization.
9. Common Misoperations & Prohibitions
❌ Dismantle equipment without LOTO lockout → Isolate energy source first always.
❌ Use non-genuine spare parts or alternative lubricants → Cause precision failure, accelerated wear and hygienic risks.
❌ Excessive lubrication (especially hygienic zone) → Lead to product contamination and bacterial breeding.
❌ Unqualified CIP concentration & temperature → Incomplete cleaning, limescale accumulation and hygiene hazards.
❌ Ignore hygienic validation → SIP and sterile test must be passed before production after overhaul and spare parts replacement.
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**Replacement parts are not made by the original manufacturer. KRONES®, SIDEL®, KHS®, SACMI®, AROL® SIG®, SIPA®, TECH-LONG®, etc. These SPARPAE RTS are replacement parts for OEM parts, mainly made in China and sold all over the world.
KRONES® Krones spare parts is a registered trademark of KRONES AG. BSC is not a licensee of KRONES AG, nor are BSC parts approved or authorized by KRONES AG
KHS® KHS spare parts is a registered trademark of KHS GmbH. BSC is not a licensee of KHS GmbH, nor are BSC parts approved or authorized by KHS GmbH
SIDEL® Sidel spare parts and SBO® spare parts are registered trademarks
