Everards Brewery - Keg and Cask Filling System

The Client

Everards Brewery operates from a stunning new 70-acre facility at Everards Meadows in Leicestershire, UK. The brewery produces a selection of ales, including the much-loved 'Tiger Bitter', and required a comprehensive system to handle the full production of the Everards beer brand.

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The Challenge

The brewery needed a bespoke keg and cask washing and filling line capable of processing up to 90 firkins per hour. The system required complete integration of washing, filling, and transport processes, with automated conveyor systems to ensure smooth operation throughout the production cycle. The solution needed to accommodate both internal and external washing requirements, whilst maintaining efficiency and hygiene standards essential to brewery operations.

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The Solution

Central Conveyors designed and installed a comprehensive automated system incorporating the following bespoke equipment:

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• Cask and keg loading start-off process featuring twin plastic modular conveyor systems

• 1500mm wide plastic modular conveyor with a guide system to facilitate single-file entry into the washing plant

• Cask and keg external washers with a label removal booth and automatic conveyor system

• Gravity roller conveyor system for cask accumulation area, allowing operator access for loading

• Three-station internal washing unit with four heads and 1000-litre tank capacity

• Mobile gravity roller unit with storage capacity for four casks, enabling transport from the washing unit to the filling racking machine

• Keystone press unit for cask preparation

• Twin-head counter pressure racking and filling unit with automatic plastic modular, twin-stand conveyor system and arrester

• Cask up-ender tipping mechanism for orientation changes

• 600mm wide cask-off plastic modular conveyor system

• 2400mm long stainless steel powered roller conveyor incorporating three lift transfer units

• Two-position automatic conveyor system for cask handling

• Keg up-ender tipping mechanism

• Plastic modular conveyor system fed from up-ender tipper unit

• 1600mm long stainless steel powered roller conveyor with single lift transfer unit

• Dedicated cask control panel for system operation

The Results

The implemented solution delivered comprehensive benefits to Everards Brewery:

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• Achieved production target of 90 firkins per hour through efficient automated processing

• Integrated washing, filling, and transport operations into a seamless production line

• Enhanced hygiene standards through automated external and internal washing systems

• Improved operational efficiency by minimising manual handling requirements

• Provided reliable automated control systems for consistent production quality

• Enabled smooth material flow through strategic placement of accumulation areas and transfer units

The system continues to support Everards Brewery's production requirements effectively, providing the capacity and reliability necessary for their brewing operations at the Everards Meadows facility.