Failure analysis of a filling valve from a Brewery's beer filler

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4 Citations (Scopus)


This paper describes a failure analysis carried out to a filling valve of a brewery beer filler. The filling valve under study is one of 120 filling valves belonging to the filler, an equipment dated 1996. This filler integrates a packaging line, in which several equipment compromise it, and the filler leads the production cadence. Hence, any malfunctioning or failure of the filler will affect the entire packaging line. The failure herein presented prevents the filling valve from performing accurately, requiring production to be stopped and the filling valve to be opened to solve the problem. The failure leads to empty and even over flooding bottles, which are subsequently rejected from the packaging line, causing a monetary waste that could be spared. Since the filler works 64,000 bottles per hour and has 120 filling valves, the failure of one filling valve could lead to 500 bottles being rejected in one hour. The main objective of this analysis is to avoid leakage and product loss. The failure is due to the existence of a solid residue deposit - identified as solidified beer - inside an area of the filling valve where only compressed air should circulate, preventing the proper movement of a compression helical spring. Until the reason for such deposit was figured out, several trials to eliminate a variety of hypothesis were carried out and, at the end, a modification in one of the parts of the filling valve was performed to avoid failure and keep the filler working accurately.

Original languageEnglish
Pages (from-to)87-99
Number of pages13
JournalEngineering Failure Analysis
Publication statusPublished - 1 Nov 2018


  • Beer filler
  • Component's redesign
  • Experimental tests
  • Failure analysis
  • Filling valve


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