Part Two: Draft Beer System Cleaning Equipment and Procedures

What did we learn in part one?

In our part one of draft beer system cleaning, we discussed that all beer systems requiring cleaning and maintenance. We covered chemical safety procedures, design considerations, replacing lines, the frequency of cleaning, the difference between acid based and caustic based cleaning, and the three types of cleaning.  We also provided links to some resources including a cleaning log and a cleaning tutorial. If you haven’t already, then check out part one here.

In part two, we will cover the draft beer system cleaning equipment as well as the procedures needed to clean your beer system. All beer systems are unique and require a cleaning procedure exclusive to that system. Additionally, no single solution works for all systems.

All systems will require both hand cleaning and some form of mechanical cleaning.  This is different from the three types of draft beer cleaning processes mentioned in part one.

• Hand cleaning: Faucets, couplers, exterior surfaces, and parts.
• Mechanical cleaning: Use mechanical cleaning to clean the inside surfaces that can’t be reached by hand cleaning.

There are two types of beer system cleaning systems:

• Electric Pumps
• Static or Pressure Pot Cleaning

Electric Recirculation Pumps

Electric cleaning is the preferred method of cleaning beer systems. Pumps recirculate chemicals at an increased flow rate.  This higher rate adds mechanical cleaning action (through turbulence) during the cleaning process. Recirculation cleaning is up to 80 times more efficient than static pressure pot cleaning. 

 

Cleaning considerations

• Reverse the cleaning flow from normal serving flow during cleaning.
• The flow rate during cleaning should be twice normal serving flow rate.
• Line pressure during cleaning should never exceed 60 psi.
• Minimum cleaning time is 15 minutes.
• If flow rate during cleaning is less than two gallons per minute, increase the cleaning time.

Increase or reduce the number of lines cleaned at one time to control the flow rate. Test the flow rate to verify the length of cleaning time. It can also help determine if the correct number of lines are connected for cleaning.

Static Pressure Pot Cleaning

Pressure pot static cleaning is not the recommended cleaning option because it is a much less effective cleaning method.

• Static cleaning does not allow the mechanical cleaning action flow cleaning provides.
• The static cleaning also requires longer cleaning time to make up for its reduced effectiveness.
• We recommend pressure pot static cleaning for short runs of less than 15 feet. Cleaning time is 20 minutes of chemical contact before rinsing.

 

Equipment Used In Recirculation Flow Cleaning

Here is some of the equipment required for flow cleaning.

• Recirculation Pumps
• Couplers
• Cleaning Coupler Adapters
• Jumper Lines
• Fill Bucket (water bucket)
• Chemical Bucket
• Measurement Container (for flow)
  • Pitcher
  • Specific Volume Container

Check Before Starting Cleaning Starts

Perform cleaning procedures in the proper order. Here are some items to check before cleaning starts. Each system may not require all of these.

1. Turn the gas supply off to beer pumps.
2. Set flow valves to backflush if your beer pump has this setting. If not, check with your installer for a different cleaning method for your system.
3. All lines that split to feed more than one tap must be separated and cleaned as individual lines.

Recirculating Flow Cleaning Procedure Steps:

1. Connect couplers without engaging the check valve ball override.
2. Remove faucets (Taps) from their shanks.
3. Connect the second set of couplers when cleaning four lines for kegs in series.
   1. Connect couplers to gas lines
   2. Place series caps with check ball lifters on all other couplers
4. Connect out hose from pump to first tap shank.
   • When cleaning four lines:
     • Attach out hose from recirculating pump to the first shank
     • Connect other shank in the second loop with a jumper hose
     • Attach drain hose to the second faucet
     • Verify drain hose and out hose are not on the same loop

5. Fill water bucket with warm water and place in hose into water.
   1. Turn on recirculating pump and flush all beer from lines
   2. Discard flushed beer before continuing
6. Turn recirculating pump back on and allow water to run into a clean chemical bucket.
   1. Measure flow rate using a measurement container
   2. Verify flow rate of two gallons per minute
      • If flow rate is too low when cleaning four lines:
        • Clean each line individually
        • Clean for a longer time
7. Fill bucket until it submerges the end of the in hose.
8. Add the correct chemical amount to achieve 2% – 3% cleaning solution based on age and condition of lines.
   1. Move the in hose from fresh water bucket to chemical bucket
   2. This closes the loop and drains into the same bucket from which the cleaning solution is pulled
9. Allow chemicals to recirculate for a minimum of 15 minutes.
   1. This is a perfect time to clean the external surfaces of the beer system including faucets
   2. Fill clean bucket with cold water for rinse cycle
10. When cleaning time is up, move in hose from the chemical bucket back to clean water bucket filled with cold water.
11. Continue recirculating pumping until all chemical has been removed from the lines.
    1. Dump chemical bucket as needed
    2. Continue until it flushes all solid matter from lines
12. Shut off the recirculating pump and reassemble the system.

Check At End of Flow Cleaning

1. Return all system components to original function.
2. Reassemble all lines that were split to clean individually.
3. Check to verify beer pump flow valves are not set to backflow.
4. Reset FOB’s and diverters.
5. Turn the gas supply on to beer pumps.

Equipment Used In Static Or Pressure Pot Cleaning

Pressure pot cleaning uses less equipment for the cleaning process than flow cleaning. It relies on the chemicals sitting statically in the lines for a set amount of time for cleaning. Therefore, pumps, measurement flow containers, and in and out buckets are not required.

• Cleaning Canister
• Series Caps

Static Cleaning Procedure Steps:

1. Fill cleaning canister with clean water.
2. Untap keg and tap the cleaning canister.
3. Open the faucet until the clean water flows and has flushed all beer from the system.
4. Untap cleaning canister.
5. Fill the cleaning canister (or use a second canister) with the proper chemical amount to achieve a 2%–3% cleaning solution based on the age and cleanliness of the beer lines.
6. Tap the chemical canister.
   1. When applying Co2 to a cleaning canister containing a caustic cleaning solution the C02 will weaken the solution.
   2. Do not shake the solution or agitate it more than necessary
   3. Let the solution stand no longer than necessary
   4. Do not use “spitting action” pressure pots which inject C02 into the outfeed solution
7. Open the faucet until water is flushed and the chemical solution is seen pouring from the faucet.
8. Shut off the flow and untap the chemical canister.
9. Shut off gas supply on pneumatic pump systems.
10. Remove faucet and clean before replacing the faucet.
11. Retap the chemical canister.
12. Refill the lines with cleaning solution and let set for 20 minutes or more.
13. Untap the chemical canister.
    1. Retap clean cold water canister or
    2. Clean chemical canister and fill with clean cold water before retapping it
14. Open the faucet and flush cleaning chemical until clean water flows from the faucet and no solid matter is in the water.
15. Untap the cleaning canister and retap the keg.
16. Finish by pouring beer until it flows clear.

Check At End of Flow Cleaning

1. Return all system components to original function.
2. All lines that were split to clean individually need to be reassembled.
3. Check to verify beer pump flow valves are not set to backflow.
4. Reset FOB’s and diverters.
5. Turn the gas supply on to beer pumps.

Glycol Chiller Cleaning

Many systems also have glycol chillers as additional equipment to cool beer trunk lines. The glycol chillers require scheduled cleaning in addition to the flow and static cleaning of beer lines themselves. Glycol chillers are frequently seen in long draw beer systems and help maintain the beer temperature over long runs between keg and tap.

Additionally, it is much more expensive to replace a glycol chiller than it is to maintain it properly. Therefore, the chiller should be cleaned and maintained along with your beer line cleaning and maintenance program.

These checks should be performed along with normal beer line cleaning.

Glycol Chiller Cleaning Considerations:

1. Keep the cover of the glycol bath closed to prevent humidity from diluting its strength.
2. Verify the temperature of the glycol bath is at the correct temperature.
3. Check the pump motors for proper operation and fix or replace as needed.
4. Check motors for smooth operation and normal temperatures with no overheating.
5. Listen for any noises that may indicate wear or issues.
6. Check pumps, connections, insulation, and overall condition of the glycol chiller system for any signs of problems.
7. Inspect condenser for dirt or clogged air flow. Remove and clean grills, filters, condenser fins, and the unit as needed at least every quarter.
8. Inspect trunk lines for ice buildup, leaking, and missing insulation when performing line cleaning or at least every six months.
9. Check glycol strength and viscosity of the glycol-water mix at lease every six months.
10. Check the freezing point of glycol-water mix every 18 months using a refractometer using manufacturers recommendation for glycol concentration. Replace mix as needed.

Conclusion

All these cleaning steps and techniques will help you maintain a proper draft beer system for your establishment. If you need additional assistance or have questions about what you have read, then please feel free to contact us so that we can clarify or help answer your questions.

Resources:

Download our Cleaning Log

Additional Information for Beer System Cleaning:

• Brewers Association
• How to clean draft beer lines: Circulation Method