Problems on this page:
Kegs not clean inside
Hits OEE: Quality
Symptoms: Micro tests or inspections find soil or residue in washed kegs.
Detergent concentration or temperature low
Check the detergent tank concentration and temperature against the programme.
Spray time too short
Check the programme times for each step.
Dried residue in returned kegs
Pre-rinse kegs that come back with old product.
Head seals leaking so pressure is lost
Check the washing head seals.
Prevention: Micro checks on washed kegs on a fixed schedule.
Steam sterilisation not reaching temperature
Hits OEE: Quality
Symptoms: The steam step alarms or the keg temperature stays below the set point.
Steam pressure low
Check the steam supply pressure at the washer.
Condensate not draining from the keg
Check the drain valve and timing in the steam step.
Steam valve slow or sticking
Service the steam valve.
Steam time too short
Check the programme time.
Prevention: Steam step temperatures recorded per keg.
Counter pressure in the keg wrong
Hits OEE: Quality
Symptoms: Kegs leave the washer with too little or too much CO2 pressure.
Gas supply pressure low
Check the gas supply and the regulator setting at the washer.
Pressurising valve leaking
Service or replace the valve that pressurises the keg.
Spear seal leaking
Reject kegs that lose pressure and send them for spear maintenance.
Programme step skipped or shortened
Compare the programme on the washer with the approved programme.
Prevention: Keg pressure checked on samples.
Leaking spears found
Hits OEE: Quality
Symptoms: Kegs leak at the spear during washing or after filling.
Spear seals worn
Send the keg for spear maintenance and record its number.
Spear damaged by handling
Remove the keg from use until the spear is replaced.
Keg neck damaged
Inspect the neck thread and sealing face for damage.
Spear not tightened after service
Check the spear fitting torque after every spear service.
Prevention: Leaking kegs tagged and sent for repair.
Washing head leaking
Hits OEE: Availability
Symptoms: Liquid or steam escapes at the head coupling during the cycle.
Head seals worn
Replace the washing head seals on the maker interval.
Keg not centred under the head
Check the keg guides and centring for the keg size.
Clamping pressure too low
Check the air or hydraulic pressure that clamps the head on the keg.
Damaged spear top
Reject the keg so it does not damage the head seals.
Prevention: Head seals replaced on schedule.
Detergent use too high
Hits OEE: Performance
Symptoms: Detergent is topped up more often than planned.
Detergent carried into the rinse
Check the drain and blow-out steps between detergent and rinse.
Leaks in the return line
Find and repair leaks in the detergent return line.
Concentration set higher than needed
Check the concentration setting against the supplier range.
Tank dumped more often than needed
Set the dump interval from the tank condition, not only the calendar.
Prevention: Detergent use recorded weekly.
Kegs jamming on the conveyor
Hits OEE: Availability
Symptoms: Kegs jam at turners or transfers.
Keg turner timing wrong
Check the turner timing against the conveyor.
Dented kegs catching on guides
Reject dented kegs at the infeed.
Guides worn
Replace worn guides and wear strips.
Conveyor chain worn or stretched
Adjust or replace the chain.
Prevention: Jams recorded.
Damaged kegs reaching the washer
Hits OEE: Quality
Symptoms: Kegs with dents or damaged fittings are washed and filled.
No inspection at the infeed
Inspect kegs for dents and damaged fittings before washing.
Reject station not used
Use the reject station and record why each keg was rejected.
Returned kegs not sorted
Sort returned kegs before they join the washing queue.
Damage hard to see at line speed
Train staff on what to look for and give them time at the infeed.
Prevention: Damaged kegs recorded.
Hot detergent or steam escaping
Hits OEE: Availability
Symptoms: Hot liquid or steam escapes near operators.
Guard or cover open during the cycle
Keep guards closed; hot caustic and steam cause serious burns.
Drain hose loose
Secure drain hoses so they cannot whip or spray.
Valve failing open
Service the valve and test it before restarting.
Head lifting off the keg under pressure
Check the head clamp and the keg position.
Prevention: Guards and hoses inspected daily; protective equipment worn.
Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.
Related equipment guides: filling machine · CIP system · steam boiler · conveyor · palletizer · fermentation tank
Stop the same fault coming back
Recurring keg washer stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.
Book a Fabrico demo
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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover