Our service team faced a unique challenge servicing a valve installation for one of the leading beer producers in Europe.
CUSTOMER PROBLEMS
The client was struggling with a growing microbiological problem in the installation. Their internal tests showed excessive bacteria growth within the system and difficulties in cleaning it. Even after thorough cleaning, swabs still showed the presence of bacteria. This resulted in unplanned production downtime and reduced plant efficiency. The main challenge for the Tapflo service department was to ensure the hygiene of the installation, which required not only equipment maintenance but also a thorough assessment of the system’s cleanability in the CIP (Cleaning in Place) process. The task involved servicing 3 valve manifolds, which together consisted of 116 valves.
TAPFLO SERVICE ACTIONS
3 valve manifolds
116 hygienic valves
excessive bacteria growth despite cleaning
unplanned production downtime
limited time for service

Valve inspection – assessment of surface condition before seal replacement.
- Comprehensive valve service: our 6-person team disassembled the valves, inspected the surfaces, replaced seals and o-rings, and assessed the quality of the installation.
- Hygiene system assessment: we verified whether the installation met hygiene requirements and was capable of effective self-cleaning (CIP). The results of our analysis allowed for a better understanding of the causes of the developing microbiology.
- Functional tests: after the maintenance was completed, each valve was filled with water and then opened and closed several times and moved to the self-cleaning position in the CIP process. The tests confirmed the full functionality of the devices and compliance with the hygiene requirements of the brewing industry.
RESULT


Due to the client’s tight production schedule, we only had 2 and a half days to complete the entire service. Our team completed the task within the allotted time. We serviced all 116 valves, which meant a full inspection and repair of almost 50 valves per day!
The hygiene analysis after the maintenance proved that the work we carried out minimized the risk of further bacteria growth. Our actions not only minimized production downtime for the producer but also ensured the operational safety of the installation in the future.
The client, previously struggling with problems resulting from the developing microbiology, appreciated our quick response, flexibility, and comprehensive service. The high quality of the work performed strengthened our cooperation with the leader of the brewing industry.
Take advantage of our service – read more on the Tapflo service department page