CCL-45 Canning System - Owners Manual - 011718

CRAFT CANNING SYSTEM - OWNERS MANUAL
CCL-45 - COUNTER PRESSURE FILLER

SH-45 - SINGLE HEAD SEAMER
Codi Manufacturing, Inc. | 14352 W. 44th Ave. Golden, CO 80403 | 303-277-1542 | www.codimfg.com
Table of Contents
Technical Specification for Ideal Product and Filler/Seamer Operation ............................................................................ 5

Overall Dimensions – CCL-45 with SH-45.............................................................................................................................. 6
Installing the Canning Line ......................................................................................................................................................... 7
Brewery/Product Condition Checklist.................................................................................................................................... 13
Cleaning & Sanitation ................................................................................................................................................................ 14
Startup Clean In Place (CIP) – Automatic Operation ...................................................................................................... 14
Canning ........................................................................................................................................................................................ 17
Filling........................................................................................................................................................................................ 17
Adjustments to Filling Speed ........................................................................................................................................... 20
Seaming .................................................................................................................................................................................... 22
Setting Seaming Operations ............................................................................................................................................. 23
Tools Required .............................................................................................................................................................. 24
Critical Adjustments ..................................................................................................................................................... 24
Pin Height ...................................................................................................................................................................... 24
Spring Pressure .............................................................................................................................................................. 25
1st Op and 2nd Op Rolls ................................................................................................................................................ 26
Canning Line Change Over – 200 to 202 ........................................................................................................................... 28
Tools Required................................................................................................................................................................... 28
Order of Change Over ..................................................................................................................................................... 28
Lid Dropper Change Over Process ................................................................................................................................ 28
Seamer Screw Change Over Process .............................................................................................................................. 28
Seaming Chuck Change Over Process ........................................................................................................................... 28
Seamer Timing Adjustments – Change Over Process ................................................................................................. 29
Filling Screw Change Over Process ................................................................................................................................ 29
Fill Head/Centering Bell Change Over Process ........................................................................................................... 29
Filling Operation Adjustments – Change Over Process ............................................................................................. 29
Perform Pressure Test ...................................................................................................................................................... 29
Twist Rinse Change Over Process .................................................................................................................................. 29
Quality Assurance ....................................................................................................................................................................... 30
Low Fill Evaluation ................................................................................................................................................................ 30
Seam Inspection ..................................................................................................................................................................... 30
A Finished Double Seam ................................................................................................................................................. 30
Seam Inspection Equipment............................................................................................................................................ 31
External Seam Measurements.......................................................................................................................................... 32
Revision: A Codi Manufacturing, Inc.

Date: 01/17/2018 Craft Canning System – Owners Manual 2
Teardown Seam Inspections ............................................................................................................................................ 33
Cover Hook Tightness ................................................................................................................................................. 33
Short Cover Hook ........................................................................................................................................................ 34
Long Cover Hook ......................................................................................................................................................... 35
Short Body Hook .......................................................................................................................................................... 36
Long Body Hook .......................................................................................................................................................... 37
Long Seam Width ......................................................................................................................................................... 38
Short Seam Width ......................................................................................................................................................... 39
Seam Bumps .................................................................................................................................................................. 40
Compound Squeezing .................................................................................................................................................. 41
Sprung Seam .................................................................................................................................................................. 42
Hairpins .......................................................................................................................................................................... 43
Visual Double Seam Inspection ...................................................................................................................................... 44
Mushroomed Flange..................................................................................................................................................... 44
Sharp Seam..................................................................................................................................................................... 45
Droop ............................................................................................................................................................................. 46
Vee .................................................................................................................................................................................. 47
False Seam ...................................................................................................................................................................... 48
Knocked Down Flange ................................................................................................................................................ 49
Damaged Cover Curl.................................................................................................................................................... 50
Dead Head or Skidder .................................................................................................................................................. 51
Mismatch ........................................................................................................................................................................ 52
Body Buckling ............................................................................................................................................................... 53
Wooling .......................................................................................................................................................................... 54
Creasing .......................................................................................................................................................................... 55
Dissolved Oxygen (dO2) Testing ......................................................................................................................................... 56
Combating Dissolved Oxygen (dO2)................................................................................................................................... 57
CO2 Testing ............................................................................................................................................................................. 58
The Handy-Dandy Slow Force Carbonation Chart featuring Pressure vs. Temperature in Degrees Fahrenheit ... 60
HMI Defined............................................................................................................................................................................... 62
Common Buttons and Windows on All HMI Screens ..................................................................................................... 62
Initialize Screen ....................................................................................................................................................................... 63
Auto CIP Screen ..................................................................................................................................................................... 64
Manual Operation Screen...................................................................................................................................................... 66
Automatic Operation Screen ................................................................................................................................................ 69
Setup Screen ............................................................................................................................................................................ 71

Recipes Screen ........................................................................................................................................................................ 73
Trends and I/O Screen ......................................................................................................................................................... 74
Alarms Screen ......................................................................................................................................................................... 76
Seamer Screen ......................................................................................................................................................................... 78
Parts Detail - CCL-45 - Counter Pressure Filler .................................................................................................................... 80
Parts Detail - SH-45 - Single Head Seamer ............................................................................................................................ 81
Maintenance ................................................................................................................................................................................ 82
Troubleshooting ......................................................................................................................................................................... 84
Works Cited ................................................................................................................................................................................. 88
Revision History ......................................................................................................................................................................... 89
Appendices .................................................................................................................................................................................. 90
Appendix A: Neugart Planetary Gearbox P/N WPLE080 & PLPE070 Operating Manual...................................... 90
Appendix B: Joyce-Dayton Jack P/N JD-WJ1000I4S-004.00-STDX-STDX-X Technical Data .............................. 94
Appendix C: System Plast Bearings P/N UCFH206-20-SS-CEC Data Sheet .............................................................. 98
Appendix D: Anderson-Negele Pressure Transmitter P/N HH071G004A0A000 Data Sheet............................... 101
Appendix E: GEA Fill Head Valve P/N HLA/P-OD3/4”/-MZ-0000Z-1J/52/0 Technical Data ...................... 103
Appendix F: Tapflo Pump P/N T80-STS Technical Data ............................................................................................ 112
Appendix G: SEW Drive Motor P/N DRN80M4_FF_DH Technical Data ............................................................. 122

Technical Specification for Ideal Product and Filler/Seamer Operation
Ideal Product Conditions
Product Temp: 29-35°F

Product Carbonation Level: < 2.8
Supply Tank Pressure: 8-15psi
Product Dissolved Oxygen Level: < 10 ppb in brite tank
*Dissolved Oxygen as low as possible
Machine Requirements
Counter Pressure Filler w/Seamer

(L x D x H): 84” x 34” x 70”
Weight: 1300lbs
Electrical Power Supply
208-240VAC 3 phase, 60Hz, 27A

Optional:
380-500VAC 3 phase, 50/60Hz, 13A
Air
Air Pressure Input: 100-110psi

Minimum Compressed Air Line I.D. = 3/8" (minimize splits) Dedicated
Air Consumption: 11scfm
Air Quality: Compressed air must be clean and dry in accordance with ISO 8573-1:2010
CO2/Nitrogen
Type of CO2: Beverage-Grade CO2

CO2 Pressure Input: 60psi
Minimum CO2 Line I.D. = 1/2” (minimize splits direct from dewer or supply) Dedicated - No Regulators in Line
CO2 Consumption:
50lbs per 100 cases of 16oz cans
35lbs per 100 cases of 12oz cans
Supplemental CO2 Bottles: 50lb, Grade 3-A
Brewery Hose I.D. = 1-1/2” Tri-Clover Connection

Filler Tank Pressure Rating = 45psi
*Note: Filler tank pressure must be greater than brewery tank pressure (pushes product into filler tank). Never
backflow into brite tank.

Overall Dimensions – CCL-45 with SH-45
2’-10”
Figure 1: CCL-45 with SH-45
7’-2”
7’-0”
Figure 2: CCL-45 with SH-45 Side View
3’-4”
Figure 3: CCL-45 with SH-45 Front View

Installing the Canning Line
1. Position the filler as close to the brite tank as possible. Once in place ensure the filler is level. For fixed lines
with feet installed adjustments can be made at the feet. For mobile of fixed lines with casters installed it may
be necessary to place blocks or shims under the wheels to ensure the equipment is level. Ensuring the
equipment is properly level is essential for consistent filler and seaming operations.
2. Align can discharge conveyor with seamer and attach at rear connection point. See Figure 4.
Figure 4: Single Head Seamer Discharge Conveyor Rear Connection

3. Adjust discharge conveyor height with cart telescoping slots so the seamer outfeed dead plate is slightly
above the discharge conveyor belt. The gap between the dead plate and belt should be just large enough for
a business card to fit in. See Figure 5.
Figure 5: SH Seamer Discharge Conveyor Dead Plate Alignment

4. Install the twist rinse and legs to the filler infeed. Make height changes at the legs using the adjustable feet.
See Figure 6. Verify that track work is not pressing down on the filler conveyor belt. See Figure 7.
a. If using a depalletizer to feed cans, adjust the twist rinse track infeed such that the rails sit slightly
below the depalletizer discharge conveyor.
Figure 6: Twist Rinse with Hand-fed Can Receiver
Figure 7: Twist Rinse Mount

5. Connect water or ionized air to twist rinse and discharge conveyor rinse.
a. If using water on the twist rinse, install a line splitter on the water line from the brewery. Connect one
line from splitter to the “water in” on the filler and the other line to the discharge conveyor rinse.
Connect the “water out” line on the filler to the twist rinse. See Figure 8.
OUT
IN
Figure 8: Water Inlet & Outlet Valve on the Filler
b. If using a sanitizer keg on the twist rinse, set regulator on the keg to 40psi and connect the line from
the sanitizer keg to “water in” on the filler. Connect the twist rinse line to the “water out” on the filler.
See Figure 8.
c. Connect the brewery water line directly to the discharge conveyor rinse.

6. Connect compressed air line to “Air” in on the filler, using an air regulator to check that the air supply is dry
and clean. See Figure 9. Air inlet connection size: 1/4” NPTF
NOTE: Air can be better managed with a three-way air manifold.
7. Connect brewery CO2 line to “CO2” in on the filler. See Figure 9. CO2 inlet connection size: 3/8” NPTF
.
IN
IN
Figure 9: Air & CO2 Panel
8. Connect Main Power supply to the connection point provided on the CCL-45 electrical panel. Power up the
equipment.
a. Confirm e-stop operation by toggling each e-stop independently (3 Places). When triggered, an alarm will
display at the top of the HMI screen. To reset the alarm, pull out the e-stop that was triggered and press
the Master Relay Reset button located on the side of the HMI enclosure.
Figure 10: E-Stop Alarming
MASTER RESET RELAY BUTTON
Revision: A Codi Manufacturing, Inc. Figure 11: Master Reset Relay Button
b. Verify pneumatic operations by toggling the separate functions using the Manual Operation Screen.
Confirm the lifter is lifting, knife is retracting, pusher is pushing, fill heads move, ETC.
Figure 12: Pneumatic Operations

c. Index 5 cans under fill heads to verify can placement. Jog forward or backward to align being sure to
always end in a forward movement.
Figure 13: Pos. Screw Window

d. Pressurize cans to ensure fill heads are sealing correctly.
i. Turn on CO2 to Cans
Figure 14: CO2 To Cans Window - Off

ii. Lower the fill heads
Figure 15: Fill Heads Window

iii. Turn off CO2 to Cans
Figure 16: CO2 To Cans Window - On

iv. Verify cans are holding at least 45psi.
Figure 17: Fill Valve Current Status

e. Verify tank is holding preset pressure (35psi) keeping in mind that it may take a moment for the pressure
to level out. If pressure will not hold or drops drastically, check all connections with snoop fluid with focus
on the tank gaskets in particular. If a leak is present bubbles will form.
NOTE: Ensure fluid is present in the system up to the fill valves or pressure will not hold.
Figure 18: Filler Tank Status Window

f. Using the Seamer Screen, select the Jog To button provided in the Seam Op1 Start window.
Figure 19: Seamer Op1 Start Window

i. Verify OP1 timing using the timing marks placed on the shaft and on the bearing, both should align.
Perform adjustments as necessary to timing belt.
ALIGNED MISALIGNED
Figure 20: Op1 Timing Marks
g. Select the Jog To button provided in the Lid Screw Cutting window.
Figure 21: Lid Screw Cutting Window

i. Verify Lid Screw Cutting timing using the timing marks placed on the shaft and on the bearing, both
should align. Perform adjustments as necessary to timing belt ensuring shaft 1 stays timed with
encoder.
ALIGNED MISALIGNED
Figure 22: Lid Screw Cutting Timing Marks
h. Select the Jog To button provided in the Can At Dwell Start window.
Figure 23: Can At Dwell Start Window

i. Verify Can At Dwell timing using marks placed on screw and bearing housing, both should align.
Perform adjustments as necessary to timing belt.
ALIGNED MISALIGNED
Figure 24: Can At Dwell Timing Marks
i. Verify induction sensor placement. The mounting bracket should be butted up with the side rail bracket.
Figure 25: Induction Sensor Placement

j. Verify there are ends present in the end chute. A full sleeve is desired to limit need for constant handling.
k. Manually trip the induction sensor for can at lid drop. Verify ends are being separated, pushed, and travel
unimpeded down the chute.
l. Fill a can with water. Jog the can of water into the seamer stopping it just before end placement. Verify lid
dropper height and that the lid is centered on the can. Perform adjustments as necessary using 3 bolts
located on top of seamer plate.
m. Place the can lifter in manual mode. Jog the can farther into the seamer so the can moves onto the lifter
plate. Ensure the can is centered on the lifter plate. Perform adjustments as necessary.
n. Jog can back off the lifter plate. Place the can lifter back into auto mode.
o. Run the can through the seamer and perform an inspection of the seam. Adjust OPs as necessary per the
Setting Seaming Operations section provided below on Pg. 23.
9. Reinstall any guards that were removed.
Brewery/Product Condition Checklist Yes N/A
1. Check the product to make sure it is within specification. Out of spec product has the potential
for higher losses.
2. Ensure your equipment has been laid out in the correct order of operation. Order of equipment
in canning line (from right to left) should be:
a. Twist Rinse with Legs & Infeed Chute
*If used, depalletizer will feed the infeed chute of the twist rinse.
b. Counter Pressure Filler
c. Single Head Seamer
d. Discharge Can Rinse Conveyor
e. As applicable, position CIP Cart between brite tank and filler in a location that allows a
brewery hose to connect from the CIP Cart to both.
3. Ensure canning system is level.
4. Ensure all plumbing and pneumatic connections have been made and are secure.
a. Compressed air must be clean and dry in accordance with ISO 8573-1:2010. If particles
or water are found present in the air, the warranty provided by Codi Manufacturing is
VOID.
5. Ensure all motors have been confirmed for proper operation. Confirm rotation of all belting.
6. Counter Pressure Filler:
a. Ensure fill head alignment and filler screw timing have been verified.
b. Ensure fill heads seal correctly to the cans.
c. Perform CO2 volume and flow test.
7. Single Head Seamer:
a. Ensure seamer infeed screw timing have been verified.
b. Ensure sensors are correctly seeing cans.
c. Ensure lid cutter is properly sensing, cutting and placing lids.
d. Ensure cans are transferring over the plates and onto lifter without being impeded.
e. Ensure 1st Op and 2nd OP rolls are engaging during the lift.
f. Ensure cans do not bounce during this entire process.
g. Ensure Pin Height is set correctly.
h. Ensure Spring Pressure is set correctly.
Operator: Date:
______________________________________ ___________________
Codi Manufacturing Field Service Technician: Date:
______________________________________ ___________________

Cleaning & Sanitation
Startup Clean In Place (CIP) – Automatic Operation
1. Ensure the handle on the recirculation manifold is turned from Run to CIP.
Figure 26: Recirculation Manifold Handle

2. Verify hose from CIP equipment is connected to the CCL-45 tank inlet.
3. Verify recirculation hose is running back to CIP equipment.
4. Make sure 5 cans are properly indexed under the fill heads.
5. Verify CCL-45 tank pressure is at 0psi.

6. Press & Hold the Auto CIP button found on the Auto CIP screen.
Figure 28: AUTO CIP Screen

7. Follow the on screen prompts.
a. Press Start button that appears next to Step 1. The pump will start to fill the tank. Once the tank
reaches 100%, fluid will begin to flow into the indexed cans.
Figure 29: CIP Step 1 - Start
Figure 30: CIP Step 2 - Start
b. When the cans are full press the Start button that appears next to Step 2. The fill heads will come
down. CIP fluid then pumps through and recirculates through the system.
Figure 31: CIP Step 2 - Running

c. Once the preset time interval has been reached the pump will stop running and remaining product
will be pushed through the system.
Figure 32: CIP Step 3 - Running

8. When the CIP process is finished, from the Manual Operation Screen, open all fill valves to release
potential vacuum in the fill lines. Ensure tank is at 0psi.
Figure 33: Manual Operation Screen

9. Open the ball valve located at the bottom of the tank to release any fluid remaining in the tank.
10. Dump and discard cans that were indexed under the fill heads.
11. REPEAT steps outlined above for however many processes you want to run. Dispose of or store
recirculated chemicals and water per your applicable Local, State and Federal regulations.
Canning
Filling
CAUTION: SOMEONE MUST BE PRESENT/MONITORING THE CRAFT CANNING SYSTEM AT ALL
TIMES WHILE IN OPERATION. IF A CAN SLIPS OR JAMS YOU NEED TO BE ABLE TO REACT
QUICKLY.
1. Ensure filler has been properly cleaned and tank is empty of any cleaning product.
2. Ensure the handle on the recirculation manifold is turned from CIP to Run.
Figure 34: Recirculation Manifold Handle
3. Press and hold the “Initialization Stopped” button found on the left hand side of the Initialize screen. See
Figure 35.
Figure 35: Initialize Screen

4. Follow Step 1 prompt to purge the tank of O2. Select a minimum of 2 Purge Cycles at 15psi for the Tank
Purge Pressure. Press the Start O2 Purge button.
Figure 36: Initialization Step 1

5. Follow Step 2 prompt. Select Recipe for product being ran. When the recipe is selected tank pressure and
level will set itself. If Recipes are not stored, set tank pressure and level manually. Press the Pressurize Tank
button.
6. Follow Step 3 prompt. Manually open the supply valve from the Brite Tank and the butterfly valve located at
the tank inlet. Press the Confirm button that populates next to the Step 3 prompt. A prompt will appear asking
if the tanks is empty, press the Continue button.
Figure 39: Tank Empty Confirmation Window

7. Once the tank reaches the level set point, a Start Auto Fill Cycle button will pop up in the bottom right hand
corner of the HMI. Select the Start Auto Fill Cycle button. A prompt will display explaining what actions will
be taken, press the Continue button.
Figure 40: Start Auto Fill Cycle Button
Figure 41: Auto Fill Cycle Confirmation Window

8. The system will slowly ease into normal operation based on the defaults that were selected. Watch, monitor,
and perform adjustments as necessary.
a. Snift timers, throttle, and pressure drop – higher temp beer needs lower fill throttle and higher snift
times
b. If fill throttle is set too high, you will receive low fills.
c. If upping the fill throttle you also want to increase pressure drop to a certain degree.
d. Pressure drop is the sensitivity the machine has to recognizing a full can. As it is increased, it is less
sensitive and waits longer to ensure a full can.
e. Small adjustments at a time. Run for 5 cycles in between adjustments to confirm.
9. Perform seam inspections and monitor cans for low fills per your applicable Local, State and Federal
regulations.
10. Perform CIP when finished running product or in between production runs.

Adjustments to Filling Speed
Adjustments can be made in Automatic Operation (see Figure 42) to speed up or slow down the cans per minute.
Figure 42: Automatic Operation Screen

1. “Purge”
a. “Evacuate Cycles” pressurizes cans up to 20psi and then purges to 0psi, repeating for as many cycles
as input.
b. “Flow Through Purge Timer” bring CO2 straight from source flowing through the can to displace
oxygen.
c. Disabling “Evacuating Cycles” in favor of “Purge Flow Through Time” can be reduced to decrease
fill time. A range of 0.5 seconds to 1.0 seconds is recommended to allow enough CO2 to displace
oxygen in the can but may need to increase for cans larger than 12oz.
Figure 43: Purge Window

2. “Fill”
a. “Pressure Drop” and “Time” can both be adjusted to decrease fill time. “Time” waits until the set
threshold to move onto snift. The “Time” parameter can be bypassed by setting the value to
anything above the fill time for each cycle. “Pressure Drop” is preferred for quicker operation and
can be set to progressively lower increments until there are no cycle to cycle fill inconsistencies.
b. “Throttle (Tank Diff)” decreases fill time as set value is raised.
Figure 44: Fill Window

3. “Snift”
a. Snifting is used to relieve head space pressure and should be set as low as possible to maximize cycle
speed.
b. If product is agitated & foamy, a 1st snift operation can be set to a “Throttle (Choke-psi)” of 40-87psi
with a higher “Time” variable for 1-2 seconds. A 2nd snift operation can then be used to relieve head
space pressure by using a “Throttle (Choke-psi)” of 5-15psi and “Time” of 0.5-1.5 seconds.
Figure 45: Snift 1 & Snift 2 Windows

4. “Speed Control”
a. Increasing the feed rate on the “Screw Offset” parameter will decrease fill cycle time. However
attention must be paid on the filler infeed side so cans flow steady to all fill heads. Going too fast
without proper back pressure will allow gaps to form in the screw. Also as the screw offset increases,
the difference between screw and conveyor speed can result in sloshing.
b. “Seamer Offset” should be set to help control slosh and attempt to keep the infeed packed with cans
while maintaining about a 1 can gap in between cycles.
Figure 46: Speeds Window

5. “PSI” or “BAR”
a. This is the pressure within the filler tank. Increase pressure to keep agitated (or foamy) product in
solution. Lowering the tank pressure reduces the pre-fill pressure required in cans thus speeding up
cycle times. A good range is between 30-40psi (2.06-2.76 BAR).
6. “Level”
a. It is recommended that the tank level be at approximately 30% at start up and during adjustments.
Having the tank level too high has potential of allowing the beer to get too warm. Having the tank
level too low does not allow for settling time and can make packaging tough because the product is
agitated when entering the can creating excess foam. Good rule of thumb; set level to turn tank
product over 1 time/minute.

Seaming
The following are the top-level steps each can goes through in the single head seaming process:
1. Filled can is recognized by sensors and captured by the seamer timing screw causing lid to be cut.
2. Lid (end) is cut & dropped from its chute, at an interval specified by the sensor, into the lid dropper track and
placed on the can. The lid sensor sends a signal that end has been placed on the can and triggers the lifter to
lift the can.
3. The can is moved onto the seamer transfer plate and is positioned on the lifter plate.
4. The can lifter assembly now raises the can and end onto the seaming chuck, compressing the end onto the
can.
5. The first operation roll now begins seam formation, “curling” the end and can flanges together by moving in
toward the seamer chuck. The 1st operation roll then backs away when the end curl is formed under the can
flange.
6. The second operation roll now moves into the curl formed by the 1st operation, compressing the end curl and
sealing compound to form a hermetically sealed, finished can.
7. The finished can is removed from the compressive load between the can lifter assembly and the seaming
chuck.
8. Finished can moves onto the discharge conveyor for final rinse, labeling, coding and pack out.

Setting Seaming Operations
Before the CCL-45 system ships from Codi Manufacturing the machine will be set up and tested based on the
parameters given to Codi for the design of your system. Cans will be filled with water using your CCL-45, they will
be seamed and the seams will be inspected using electronic seam inspection equipment. Once the CCL-45 is installed
onsite these settings should be verified before moving into full production.
If you have samples of the cans and ends you will be running available, prior to shipment from Codi Manufacturing,
we will run those cans during Factory Acceptance Testing (FAT). If you wish to be present at Codi during FAT of
your system please send a written request to your Codi Representative at a minimum of 2 weeks prior to your agreed
upon shipment date.
While setting up the seamer operations is relatively simple mechanically, fine tuning the settings can be a tedious
process. Great care needs to be taken to prevent damage to the machine, cans and loss of product. Whenever
troubleshooting a seam or making adjustments keep the following in mind:
• While most of the can bodies made by the can manufacturers (Ardagh, Ball, Crown & Rexam) are very similar
in shape and dimension the ends they produce vary greatly. The chuck installed in your machine is set based
on the type of ends you indicated you would be running when your machine was purchased. If you change
the ends you planned on using you will need to purchase a corresponding chuck and reset various seam
parameter such as pin height. The profile and length of the chuck doesn’t allow it to be used for multiple
end types.
• Have the spec sheet from your end manufacturer on hand at all times.
• The main focus on seam inspection should be within the 1st operation roll characteristics. The majority of
defects found in the double seam will be caused during the 1st operation.
• When an adjustment is necessary, only change one variable at a time and then recheck the seam. Do NOT
change multiple variables. A small adjustment to pull one aspect of the seam into tolerance could cause
multiple other characteristics to fall out of allowed tolerances.
• Before any adjustments are made make sure the operation being adjusted is at its tightest point. Adjustments
performed on operations not at their tightest point could cause the rolls to crash into the chuck when the
seamer is powered up.
• If a severe crash is experienced the ops should be adjusted and machine should be thoroughly inspected.
Inspect the rolls for damage, ensure they still turn freely and don’t have any slivers or metal shavings built up
around the entire parameter of the roll. Inspect the chuck for damage or debris; a severe crash could cause
the shaft the chuck is attached to be out of plum possibly causing several thousandths of runout. Perform
the above mentioned inspections removing any debris found, run cans and inspect the seams then adjust
seam settings if needed.
• Keeps your hands, hair and loose clothing away from the chuck/rolls when the machine is in operation. The
force exerted by the rolls is in excess of 500lbs which will cause severe damage.
• The quality of the double seam is ultimately the Clients responsibility. Codi Manufacturing will not be
responsible for any damage caused or loss of product experienced.
• When in doubt call Codi for assistance @ 303-277-1542

Tools Required
The following are the basic tools required for making adjustments to the seamer.
• 3/4” Box Wrench • Feeler Gauges

• 5/16” Open End Wrench • Pin Height Gauge
• 1/4” Allen Wrench • Spring Force Gauge
• 1/8” Allen Wrench • Mitutoyo Can Seam Checker
• Calipers
Optional Items:
• CMC-Kuhnke/Quality By Vision Seam Saws and Video Seam Imagers
Critical Adjustments
There are four highly critical areas that will require adjustment or initial setting; Pin Height, Spring Pressure, 1st Op
Roll & 2nd Op Roll.
Pin Height
This is an extremely critical setting in the seaming process. This height sets the gap between the lifter plate and bottom
of the chuck. Consult your end manufactures spec sheet for recommended Pin Height settings. Use a Pin Height
Gauge to measure the distance between the top of the lifting plate and bottom of the chuck. With the lifter in the
raised position, center the pin height gauge between the lifting plate and bottom of the chuck, perform measurement.
DO NOT RAISE THE LIFTER WITH THE GAUGE IN THE MACHINE.
CHUCK
PIN HEIGHT GAUGE
LIFTING PLATE
Figure 48: Pin Height Gauge

Spring Pressure
Consult your end manufacturers spec sheet for recommended Spring Pressure settings. Position the Spring Force
Gauge between the chuck and lifting plate with the lifter raised. DO NOT RAISE THE LIFTER WITH THE
GAUGE IN THE MACHINE. Rotate the gauge from 0-.030 and the force will register. If an adjustment is required
use a 1/8” Allen Wrench to rotate the adjustment screw positioned directly in the center of the lifting plate. Turing
the screw clockwise will increase pressure and turning counter clockwise will decrease the pressure. Small adjustments
only; one full turn of the screw in either direction will change the force being applied by 12ft lbs. Once the spring
pressure is set it should not require adjustment although it should be checked periodically to confirm its holding and
will require adjustment with a can height change over.
While spring pressure may seem to be the most likely culprit of crushed cans it rarely is actually the cause. See details
provided below in the Visual Inspection section regarding Mismatch and Body Buckling for some potential causes of
crushed cans.
Figure 49: Spring Pressure Gauge

1st Op and 2nd Op Rolls
The adjustment method used for the Ops is the same between both but keep in mind for lateral spacing they rotate
in opposite directions. When looking at the machine from the front the 1st Op roll is positioned on your right of the
chuck and the 2nd Op roll is positioned on your left of the chuck.
Operation Recommended Height Recommended Lateral Spacing

1st Op 0.001-0.003” 0.018”
2nd Op 0.002-0.003” 0.002”-0.005”
Adjust the height of the Op using the 5/16” Wrench on the adjustment bolt (2) on the top of Op assembly. Carefully
loosen the brass tip set screw (1), set the gap required for the height with the 5/16” wrench (2), tighten the set screw
(3) and double check the spacing on the gap. Loosen but keep snug, the 3/4” set screw (3). The height will not adjust
if you leave this tight. But if you loosen too much you may cause the roll to move in/out or wiggle from side to side.
It will be difficult to fit a pin gauge or feeler gauge between the chuck and roll. An acceptable work around would be
to close the gap between them completely and then raise it back up until you see a sliver of day light coming through.
Always end on an upward motion, otherwise slack in threads could cause the rolls to contact the chuck.
(2)
(1)
(3)
Figure 50: Op Assembly – Height Adjustment

Adjust the lateral spacing using the large adjustment bolt that is positioned through the entire Op assembly. The
lateral spacing should be measured using a feeler gauge positioned between the lip of the roll and lip of the chuck.
While holding the adjustment bolt in place with the 1/4” Allen Wrench use the 3/4” Box Wrench to carefully loosen
the nut, set the gap required for lateral spacing with the ¼” Allen Wrench, tighten the nut and double check the
spacing of the gap. Always end in an outward motion.
Figure 51: Op Assembly – Lateral Adjustment
*Lateral spacing for Op1 is best done with

feeler gauges, however, for Op2 you can
bring the Op into the chuck and then back
out until you see a sliver of day light coming
through.
Figure 52: Op Assembly – Lateral Spacing

Canning Line Change Over – 200 to 202
When the need arises to change between can sizes several aspects of the system need to be adjusted.
Tools Required
The following are the basic tools required for making the change over adjustments to the filler and seamer.
• 1/2”, 3/4” & 7/16” Box Wrenches
• 5/16” Open-End Wrench
• 1/2” & 7/16” Sockets
• Allen Wrench Set
• (2) Spanner Wrenches & (2) Crescent Wrenches
Order of Change Over

Perform adjustments to the following aspects of the system in the order listed here.
1. Lid Dropper
2. Seamer Screw
3. Seaming Chuck
4. Seamer Timing Adjustments
5. Filling Screw
6. Fill Heads / Centering Bells
7. Filling Operation Adjustments
a. Preform pressure Test
8. Twist Rinse
Lid Dropper Change Over Process

1. Remove all air lines from the push-to-connect fittings on the lid dropper assembly.
2. Remove all proximity sensors, wires only.
3. Loosen 3 top bolts. (Check spacing between lid feeder and lid dropper, take a picture)
4. Remove entire old lid dropper assembly.
5. Replace with new lid dropper assembly and tighten bolts. (Make sure to leave spacing between lid feeder
and the lid dropper unit)
6. Replace all air lines and proximity wires.
Seamer Screw Change Over Process

1. Remove the 4 mounting bolts holding the seamer screw in place.
2. Remove old screw and replace with new screw.
3. Replace the 4 mounting bolts and adjust screw forward or backwards as needed. Ensure can is centered on
lifter pad.
4. Adjust guide rails so can moves easily and doesn’t get pinched or wedged.
Seaming Chuck Change Over Process

1. Using two spanner wrenches loosen the Chuck and remove it. (Left hand thread; right turn to loosen)
2. Replace with new chuck.
3. Consult the spec sheet from your end manufacturer for height and spacing adjustments.
4. Perform adjustments to the seaming operations per the Setting Seaming Operations section provided above
(Pgs 22-26).

Seamer Timing Adjustments – Change Over Process
1. Select Seamer Screen from the HMI.
2. Jog to Seam Opt. 1 – Watch cam lobe slightly start to engage and stop.
3. Jog to Lid Screw Cutting – Check that the start of the separator is facing approximately around 7 o’ clock.
4. Jog to Can at Dwell Start – Check that the seamer screw matches markings on screw and bearing plate.
5. If seam checks or timing are off adjust as necessary.
*See pages 11-12 provided above for additional details regarding seamer timing adjustments.
Filling Screw Change Over Process
1. Remove the mounting bolts holding the screw in place.
2. Remove old screw and replace with new screw.
3. Replace the mounting bolts securing the new screw in place. Hand tighten the mounting bolts, they will be
tightened later in process once indexing has been confirmed.
4. Follow the Filling Change Over Process Operation Adjustments instruction’s before torqueing the
mounting bolts.
Fill Head/Centering Bell Change Over Process
1. Remove front plate with Codi logo by removing top bolts.
2. Loosen top bolts to remove old fill heads/centering bells.
3. Replace with new fill heads/centering bells.
4. Replace front plate after performing Pressure Test incase further adjustments are needed.
Filling Operation Adjustments – Change Over Process
1. Index 5 Cans and turn off Air Supply at the regulated shut off valve on the canning line or press the Vent
button.
2. Fill heads will drop down.
3. Set the limiting shafts if needed, adjust by loosening bolts.
4. Manually lift fill heads and place cans under centering bells.
(Can 1 and 5 might seem slightly looser as the plate is slightly bowed)
5. Adjust screw forward or backwards as needed and tighten down bolts.
6. Adjust guide rails forward or backward as needed. Tighten down screw mounting bolts.
Perform Pressure Test
1. Turn air supply on.
2. Perform pressure test by setting filler bowl to 15psi.
3. Select the Manual Operation screen on the HMI.
4. Index 5 Cans.
5. Select Tank to Cans (CO2).
6. Select Lower button provided in the Fill Heads window.
7. Inspect and listen for any leaks. Adjust and repeat pressure test as needed.
8. Set limiting shafts if needed, adjust by loosening bolts
Twist Rinse Change Over Process
1. Remove ionized air or water rinse and set aside.
2. Disconnect and remove all sensors.
3. Loosen top bolts while supporting weight.
4. Slip out bottom of Twist Rinse from conveyor infeed resting section.
5. Replace with new twist rinse. Slip bottom in first, align the top, and tighten bolts.
6. Replace sensors and ionized air or water rinse.

Quality Assurance
Low Fill Evaluation
1. As cans come through the discharge conveyor, set aside 5 cans differentiated by fill heads.
2. Dry cans completely and weigh each can individually. NOTE: Low fill beer cannot be sold.
a. 12oz can target weight: 368 ± 5 grams*
b. 16oz can target weight: 496 ± 5 grams*
* Values provided above are averages. Various other factors, such as the use of shrink sleeves, will cause these
weights to change. Research local, state and federal regulations to see what is allowed in your specific area
and for the type of product you are canning.
Seam Inspection
A Finished Double Seam
The formation of the Double Seam is the result of two separate operations which have a precisely timed relationship.
During the first part of the Double Seam formation, the curled edges of the end are interlocked with the can body
flange. The end components make up three thicknesses of the Double Seam with two thickness of the can body.
Second Operation or final formation of the Double Seam will roll and compress these thicknesses into a tight seam.
Lining compound previously applied to the curled portion of the end, forms a gasket or seal within the Double Seam
to fill in minor variations or imperfections to assure you of a hermetically sealed can.
Variations in the Double Seam are determined by measurement, visual inspection and testing. (Doubleseam.com. A
Finished Double Seam. Web)
End
A Finished Double Seam. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 53: A Finished Double Seam
Seam Inspection Equipment
There are two recommended means of measuring cans; digital and analog. The double seam teardown examination is
a destructive test. Tools that are used to perform this test include a seam micrometer, countersink gauge, sanitary can
opener and nippers. Optional equipment, include a seam saw, and a seam projector or seam scope. It is very important
that the examiner know how to operate this equipment and read measurements from the micrometer, seam projector
or seam scope. It is also important that the Examiner know how to determine the tightness or wrinkle rating of the
cover hook.
When canning, there should be a minimum of one can tested every four hours of seamer operation to verify that
seams are within specifications. Seam specifications differ depending on the can size and the manufacturer. Obtain
double seam specifications from the end supplier.
Below are some examples of digital and analog seam inspection equipment that include website and part number
details. This is not an exhaustive list of all items available on the market today. Determine what best suits your set
up based on expected volume and budget for equipment.
• CMC-Kuhnke digital set up (www.cmc-kuhnke.com) *Available for purchase from Codi Manufacturing
o Seam Thickness Gauge (STG-4000MH)
o Beverage Seam Saw (AGS-2000)
o Video Seam Imager (VSI-5000)
Digital Images. www.cmc-kuhnke.com. CMC-KUHNKE, Inc. Web. 21 October 2016.
• Quality By Vision digital set up (www.qbyv.com) *Available for purchase from Codi Manufacturing
o Seam Thickness Gauge
o Seam Saw (TBS-4CB)
o Video Seam Imager (SEAMetal LT)
Digital Images. www.qbyv.com. Quality By Vision. Web. 21 October 2016.

• CanNeed digital set up (www.canneed.com) *Codi Manufacturing has not verified the quality of this equipment
o Seam Thickness Gauge (CanNeed-STG-200-D)
o Seam Saw (CanNeed-CSS-2000)
o Automatic Seam Monitor (VSM-6C)
Digital Images. www.canneed.com. Canneed Instrument Ltd. Web. 21 October 2016.
• Wilkens-Anderson Company analog set up (www.wacolab.com)

o Micrometer – Can Seam (10770-00)
o Nippers (10771-00)
o Sanitary Can Opener (10810-01)
Digital Images. www.wacolab.com. Wilkins-Anderson Co. Web. 21 October 2016.
External Seam Measurements
After visual inspection of the external seam formation, the seam width, thickness, and countersink depth should be
measured. These measurements and complete internal seam inspection should be made at least once every four
operating hours. Complete inspection of the double seam should also be made on start-up, after prolonged shut
down, after a severe machine malfunction, and after a change in can size, body or end material. Seam measurements
should be made at three points around the perimeter of the end.
Seam Height
To measure the seam height, hold the flat surface of the micrometer against the can body and turn the thimble until
the entire seam is lightly trapped between the anvil and spindle.
Seam Thickness
The thickness of the seam should be measured by balancing the micrometer and turning the thimble until the anvil
assumes the same angle as the taper for the countersink, when the micrometer grips the seam.

Countersink
The countersink or drop from the top of the seam to the end surface is an optional measurement but is useful and
easily performed using an electronic Countersink Depth Gauge equivalent to the CDG-3000 currently offered by
CMC_Kuhnke.
CDG-3000 Counter Sink Depth Gauge. www.cmc-kuhnke.com. CMC-KUHNKE, Inc. Web. 08 June 2017.
Teardown Seam Inspections

Cans that have been previously measured for external seam dimensions and visually inspected should be measured
internally for body hook and cover hook length. Optical projection and inspection of a cross-section of the seam at
one point cannot be substituted for measurement of the body and cover hooks at several points around the seam.
Physically tearing down a seam is particularly difficult as Aluminum beverage cans are flexible and can rip apart during
manual teardown.
Visual inspection of internal seam formation should include examination for such seam defects as insufficient cover
hook tightness, jumped seam, excessive droop of the cover hook and body, or end fractures.
Cover Hook Tightness

Seam tightness is judged primarily by seam thickness and the smoothness of the cover hook. Percent tightness is
expressed in terms of how far the waves or wrinkles extend from the top edge of the cover hook toward the base of
the cover hook.
Wrinkles or waves have three basic dimensions; height, depth and length. When a wrinkle extends ¼ of the length of
the cover hook, the seam is rated 75% tight; when the wrinkle extends halfway, the seam is rated 50% tight. On
curved edges, wrinkling increases as the radius of curvature decreases. For this reason, different wrinkle ratings are
specified for small diameter cans as compared to large diameter cans.
Excessive sealing compound will sometimes cause impressions on the face of the cover hook, which cannot be ironed
out. These should not be confused with loose wrinkles. The presence of an unusual amount of compound on the face
of the cover hook is usually evidence of heavy compound.
The tightness of a double seam is graded according to percentage figures. An experienced double seam inspector can
tell a good deal about tightness by the flatness of the cover hook; that is, there should not be a rounded appearance
to the cover hook. This observation can be made on a cover hook removed from a seam that has been sectioned with
seam saw or by observing cover hooks torn down by hand.
(Rippen, 77-79 & 85)

Short Cover Hook
Short Cover Hook. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 54: Short Cover Hook
Causes Corrective Action

Loose 1st Operation Seaming Roll setting. Make adjustments. See Setting Seaming Operations
section above.
Deep countersink, or excess metal used in countersink See the section on 'Deep Countersinks'.
limits the amount of metal available for cover hook
Loose 2nd Operation Seaming Roll Setting Make adjustments. See Setting Seaming Operations
section above.
Worn 1st Operation Seaming Roll groove profile Replace 1st Operation Seaming Roll.
Insufficient seaming stock caused by too small a cut Discuss with Cover Manufacturer.
edge diameter in making of cover
Excessive Lower Chuck Spring pressure Reduce spring pressure in Lower Chuck Assemblies. See
the section on Long Body Hooks.
Worn 1st Operation Seaming Roll Bearings or Roll Pin Replace worn tapered roller bearing or Seaming Roll Pin.
Make adjustments.
(Doubleseam.com. Short Cover Hook. Web)

Long Cover Hook
Long Cover Hook. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 55: Long Cover Hook

1st Operation Seaming Roll too Make adjustments. See Setting Seaming Operations section above.
tight
Excessive seaming stock caused by Discuss with Can Manufacturer.

too large a cutting edge diameter in
manufacturer of cover
Shallow Countersink depth caused Replace the Seaming Chuck.

by a worn or incorrect Seaming
Chuck
Short Body Hook created by Body Hook will affect the Cover Hook. Increase Lower Chuck
insufficient Lower Chuck Spring Spring Pressure to obtain proper Body Hook.
Pressure
(Doubleseam.com. Long Cover Hook. Web)

Short Body Hook
A condition where too little material has been provided to form the seamed can body hook which can be easily
determined or observed by tearing down the seam.
Short Body Hook. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 56: Short Body Hook
Inadequate Lower Chuck Spring Increase Lower Chuck Spring Pressure by turning the Spring
Pressure Adjustment Screw in a clockwise direction an 1/8 of a turn at a
time. The amount of pressure increase will vary depending on the
Spring used.
Excessive distance between Reset Pin Height.

Seaming Chuck and Lower Chuck
Plate
Broken or damaged Lower Chuck Replace the Lower Chuck Spring.

spring.
Long Body Hooks in the Can Shop Discuss with Can Manufacturer. A long Body Hook in the can shop
end may give a Short Body Hook end is usually associated with a can flange defect in the can body.
in the Cannery end.
Underflanged can bodies. Discuss with Can Manufacturer. The Seamer will not complete the
flanging operation.
(Doubleseam.com. Short Body Hook. Web)

Long Body Hook
A condition where too much material has been used to form the seamed can body hook which can be easily
determined or observed by tearing down the seam. If this condition is not corrected, leakers can result producing
spoilage of product.
Long Body Hook. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 57: Long Body Hook
Excessive Lower Chuck Spring pressure Reduce Lower Chuck spring pressure by turning the
Spring Adjustment Screw in a counterclockwise direction
an 1/8 of a turn at a time. The amount of decrease will
vary with the type of spring used. An exceptionally long
body hook can reduce the cover hook.
Improper Pin Height. Reset Pin Height following instructions provided in the
Setting Seaming Operations section above.
Mushroomed Flange. See section on Mushroomed flange, Pg 44
(Doubleseam.com. Long Body Hook. Web)

Long Seam Width
Excessive pressure in the 2nd operation does not produce a good seam and may stretch the metal causing an increase
in the seam width and “unhooking” or reduction of the overlap. This seam is more likely to leak then one made with
normal pressure.
Long Seam Width. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 58: Long Seam Width

Loose 1st Operation Seaming Roll. Adjust 1st Operation Seaming Roll setting according
to Instructions or Check with can cover manufacture
for proper seam dimensions.
2nd Operation too tight Check with can or cover manufacture for proper seam
dimensions.
1st Operation Seaming Roll worn beyond the Replace 1st Operation Seaming Roll.
limit.
Worn 2nd Operation Seaming Roll. Replace 2nd Operation Seaming Roll.
(Doubleseam.com. Long Seam Width. Web)

Short Seam Width
A Short Seam Width will be noticeably loose between layers of the metal when viewed through a seam projector. The
compilation of five layers of material compared to the actual seam thickness will measure differently. This type of
seam will leak because the folds of metal are not compressed together tight enough not allowing compound to fill the
voids.
Short Seam Width. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 59: Short Seam Width
1st Operation Seaming Roll too tight. Check with can or cover manufacture for proper seam
dimensions. For adjustments, see Setting Seaming
Operations section above.
2nd Operation Seaming Roll too loose. Check with can or cover manufacture for proper seam
dimensions
(Doubleseam.com. Short Seam Width. Web)

Seam Bumps
Seam Bumps are created from uneven distribution of lining compound and occur in seams from can bodies that are
butt welded rather that lapped over and soldered. Tinplate weight reduction, can body spin flanging, reduced cut
diameters of covers and Hot Filling are also contributors to Seam Bumps. Compound flows around during 2nd
Operation seam cycle in front of the 2nd Operation Seaming Roll like a wave stopping in one spot when the Roll lifts
away from the can.
Seam Bumps. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 60: Seam Bumps
Body Hook too long. Reduce the Body Hook by decreasing the
Lower Chuck Spring pressure
(Doubleseam.com. Seam Bumps. Web)

Compound Squeezing
Unlike Seam Bumps, Compound Squeezing is a condition where lining compound is forced out through the bottom
of the seam between the can body and Cover Hook and usually can be seen all around the can. Compound Squeezing
can also be seen through Seam Projector or Scope and will become visible on the inside diameter between the can
body and cover. The Seamer will usually have signs of compound building up in the seaming turret area and is mostly
due to over tight 2nd Operation Seaming Rolls.
Compound Squeezing. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 61: Compound Squeezing

Tight 2nd Operation Seaming Roll Loosen 2nd Operation Seaming Roll setting.
setting. Compile material thickness, adding
compound allowance, to determine proper
final seam thickness.
Excessive compound in covers Discuss with Cover Manufacturer
Misplaced lining compound in covers Discuss with Cover Manufacturer
(Doubleseam.com. Compound Squeezing. Web)

Sprung Seam
Usually the Cover Hook Radius is separated from the can body wall within an approximate one inch area anywhere
around the can seam periphery. The first good sign of a Sprung Seam is a variance in the Seam Thickness by .004 of
an inch or more when checking seam dimensions.
Sprung Seam. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 62: Sprung Seam
Long Body Hooks ranging above Reduce Lower Chuck or Lifter spring pressure to bring Body
.085 of an inch. Hook dimensions within specifications.
Overtight seams forcing compound Loosen 2nd Operation seam thickness to equal the compiled
to compress beyond its purpose. thickness of can body and cover layers plus allowance for the
compound. Allow compound to act as the filler and sealer
initially intended in the Double Seam.
Tight 1st Operation seams. Loosen 1st Operation seam thickness following guidelines as
to what a good 1st Operation seam should be.
(Doubleseam.com. Sprung Seam. Web)

Hairpins
Hairpins are sometimes called R's or R-ing. A cross section cut away of the seam will reveal a Body Hook that takes
the shape of an “R”. Magnification under a scope or projector of the cross section cut will show a definite resemblance
to an "R".
Hairpins. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.

Figure 63: Hairpins
Long Body Hooks and Short Cover Reduce Lower Chuck or Lifter spring
Hooks pressure to control Body Hook length.
Tight 2nd Operation seams Loosen 2nd Operation Seaming Roll

settings which forces Body Hook
Material over the cover Hook Cut Edge.
Sealing compound variations Discuss with Cover Manufacturer
(Doubleseam.com. Hairpins. Web)

Visual Double Seam Inspection
The next few pages are examples of Double Seam defects seen visually or felt by hand. Good judgement and
experience with Double Seams will save a lot of time if defects are spotted immediately. Visual inspection of
Double Seams should be made frequently and on a scheduled basis. (Doubleseam.com. Visual Double Seam Defects. Web)
Mushroomed Flange
A Mushroomed Flange is a can flange that is over formed, resulting in a long body hook. Visual inspection of the
can flange may show this condition or it may not be possible to see this until the can seam is stripped for inspection
of the body and cover hooks.
Mushroomed Flange. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 64: Mushroomed Flange

The can flange is damaged during can Check the can handling equipment to insure that there is
handling through the system a smooth transfer of cans in all areas.
Excessive Lower Chuck Spring pressure Discuss with Can Manufacturer

during manufacture of the can
Worn Lower Chuck Plate grooves on can Discuss with Can Manufacturer
manufacturing seamer
Worn can flanger dies Discuss with Can Manufacturer
(Doubleseam.com. Mushroomed Flange. Web)

Sharp Seam
This is a condition where the seam has a sharp edge around the top inside edge of the cover and is a good
indication that it has been forced over the top of the Seaming Chuck flange.
Sharp Seam. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 65: Sharp Seam

1st Operation Seaming Roll set too high or too low over Re-adjust 1st operation seaming roll groove profile
the Seaming Chuck flange height to a maximum .003 of an inch over the seaming
chuck flange when at its furthest inward travel.
1st Operation Seaming Roll set too tight See Setting Seaming Operations section above.
Seaming Chuck may be worn at the top edge of the Check seaming roll for damage and replace if necessary.
flange from 1st Operation Seaming Roll running into it Replace the Seaming Chuck and readjust the Seaming
Roll.
(Doubleseam.com. Sharp Seam. Web)

Droop
A Droop is a small portion of the seam that extends below the bottom edge of the seam width. Droops were more
noticeable in the older sanitary cans with soldered side seams, Droops appearing at or just after the lap. They can
still crop up even on todays can and cover match ups.
Droop. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.

Figure 66: Droop

Worn 1st Operation Seaming Roll Replace the Seaming Roll.
Worn 1st Operation Seaming Roll Bearing Replace the Seaming Roll Bearing.
Improper cover curl formation Discuss with Can Manufacturer
Excessive or uneven lining compound in the Discuss with Can Manufacturer

cover
Body Hook too long Check Pin Gauge Height and Lower Chuck
Spring pressure
(Doubleseam.com. Droop. Web)

Vee
A Vee, or sometimes called a Lip or Spur, is similar to a Droop only sharper, smaller and is pointed. It doesn't
always extend below the double seam like a Droop does and may appear anywhere around the seam. Heavy Vees
can be visually seen or felt with your fingers around the bottom edge of the seam width. In severe cases metal in the
cover hook will actually fold back over itself. More commonly called a Pleat.
Vee. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.

Figure 67: Vee

Improper 1st Operation Seaming Roll setting Adjust 1st Operation Seaming Roll for tightness and height
1st Operation Seaming Roll groove profile wide Replace the 1st operation Seaming Roll with a roll that has
a narrower groove profile
Worn 1st Operation Seaming Roll Replace 1st Operation Seaming Roll
Excessive seaming stock in the cut edge of the cover. Discuss with Can Manufacturer
Product entrapped in the seam Check Filling procedures for possible overfills. A Belt
Packer or Topper may be necessary to maintain the proper
head space.
Seaming panel of the cover is wrinkled. Discuss with Can Manufacturer
(Doubleseam.com. Vee. Web)

False Seam
This is a condition where the cover and body are not hooked together but each are folded over against themselves
and compressed together.
False Seam. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 68: False Seam
(Doubleseam.com. False Seam. Web)

Bent or knocked down can flange Determine if the can is damaged before or after entering
the seamer. If the can is damaged before the seamer,
check can handling equipment to insure that cans are
entering the Filler properly. Verify seamer screw timing;
see details on Pg. 11-12.
Flattened or damaged cover curl Check Separator Knife to determine if the damage is
occurring at this point. Adjust Separator Knife to provide
smooth cover transfer without any binding. If the cover
curl is damaged here, then there is more than likely a
cover feed problem resulting in jams.
Mis-assembly of can and cover See Knocked Down Flange (Pg. 49) or Mismatch (Pg. 52)

Knocked Down Flange
A condition similar to a False Seam.
Knocked Down Flange. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 69: Knocked Down Flange

Can flange damaged in can handling system Determine if the can is damaged before or after entering the
seamer. If the can is damaged before the seamer, check can
handling equipment to insure that cans are entering the Filler
properly. Check for Mushroom Can Flange. If the flange damage
is occurring in the seamer, check timing between the dwell and
1st OP timing. Verify seamer screw timing; see details on Pg. 11-
12.
Improper Cap Centering Cam alignment The Knockout Rod w/Pad height should be adjusted to lightly
control the can & cover while on their rise onto the Seaming
Chuck.
(Doubleseam.com. Knocked Down Flange. Web)

Damaged Cover Curl
A Damaged Cover Curl is a condition where the curled portion of the cover gets flattened in at one or more spots
causing the cover curl to fold back on itself rather than tuck up under the body hook.
Damaged Cover Curl. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 70: Damaged Cover Curl

Covers damaged in handling or shipping If covers are delivered in tubes or bags, the first or second
cover on either end of the bag or tube may get damaged in
the handling or shipping. The seamer operator should watch
this very carefully when loading covers and scrap all damaged
covers. The seamer operator should be extremely careful
when loading covers so not to drop the stack of covers. If
the stack is allowed to drop it may bend over the curl on the
bottom cover resting on top of the separator disc.
Improper timing or adjustment of lid dropper to Verify seamer screw timing; see details on Pg. 11-12. Verify
can height of lid dropper and can; see details on Pg. 12.
(Doubleseam.com. Damaged Cover Curl. Web)

Dead Head or Skidder
A condition where the 2nd operation seam is not finished all the way around the can.
Dead Head. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 71: Dead Head
Seaming Roll Bearings sluggish preventing the Roll from Replace the bearings.
turning
Seaming Chuck is worn, worn smooth, or under sized Replace the Seaming Chuck. To remove the Seaming Chuck,
for the cover used locate the Seaming Chuck between the 1st and 2nd
Operation seam cycle. This will place the Seaming Chuck in
an idle spot. Use spanner wrenches in holes provided around
the outside diameter of the chuck.
Caution: The Seaming Chuck has left hand threads.
Height adjustment or Pin Height of the Seaming Turret Reset Pin Height.
is too high for the can used
Lower lip of the 1st or 2nd Operation Seaming Roll Check can & cover & seaming roll combination. The
coming in contact with the can body Seaming Roll may not have the right under cut for this
application.
Insufficient Lower Chuck Spring pressure Adjust spring pressure.

Excessive vertical endplay in the Seaming Chuck Spindle Vertical endplay should not exceed .003 of an inch. If
endplay exceeds .003 replace Seaming Spindle Bearing.
Seaming Chuck radius does not match the cover radius Replace the Seaming Chuck.
Tight 1st or 2nd Operation Seaming Roll adjustment Adjust Seaming Rolls.
Oil or grease on the Lower Lifter or Seaming Chuck Clean grease or oil from the Seaming Chuck or Lower
Chuck Plate.
(Doubleseam.com. Dead Head. Web)

Mismatch
A Mismatch or Mis-Assembly is the result of the can and cover never getting settled in together during the Double
Seam process. The finished result will be part of the cover and can not connected and normally mutilated.
Mismatch. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.

Figure 72: Mismatch

Incorrect feed screw timing Verify seamer screw timing; see details on Pg. 11-12.
Improperly adjusted knock out rod The Knockout Rod w/Pad height should be adjusted to lightly
control the can & cover while on their rise onto the Seaming
Chuck.
Floating lids; too much foam Adjust fill, snift throttles, and time to achieve less foam.
(Doubleseam.com. Mismatch. Web)

Body Buckling
Body Buckling can occur anywhere up and down the can body depending on tin plate weight or material. This
usually occurs just under the finished seam and looks as though it was pushed in buckled and twisted.
Body Buckling. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.
Figure 73: Body Buckling

2nd Operation Seaming Roll set too low in relation with Adjust 2nd Operation Seaming Rolls to .006 of an inch
the Seaming Chuck flange between the Seaming Chuck flange and Seaming Roll
profile at its inward most travel.
1st and/or 2nd Operation rolls set too tight Loosen accordingly.
1st Operation Seaming Roll set too high in relation with Adjust 1st Operation Seaming Rolls to .003 of an inch
the Seaming Chuck Flange between the Seaming Chuck flange and Seaming Roll
profile at its inward most travel.
Lower Lip of 1st and/or 2nd Operation Seaming roll is Reduce lip diameter or replace with Seaming Rolls with
coming in contact with the can body Rolls that have a shallower groove profile.
Lower Chuck Spring pressure too high or broken spring Adjust to reduce Spring pressure or if broken, replace
the spring. If spring pressure is the cause for Body
Buckling, it will appear at the thinnest and weakest point
of the can body.
Pin Height set too low for the finished seamed can height See the Dead Head or Skidder defects.
being used.
(Doubleseam.com. Body Buckling. Web)

Wooling
Wooling or sometimes called 'Slivering' is a condition that is more predominant with aluminum beverage
applications and is the shaving of material from the cover or can body flange before or during the Double Seam
cycle. Fine slivers of material will pile up in the Seaming Chuck area or cover feed rails.
Figure 74: Wooling

Seaming Chuck worn or improper fit Replace Seaming Chuck or refit Seaming Chuck
to ends.
1st Operation Seaming Rolls worn Replace 1st Operation Seaming Roll
1st Operation Seaming groove profile set too Adjust 1st Operation Seaming Roll groove
high over Seaming Chuck flange profile to within .003 of an inch over the
Seaming Chuck flange. See Sharp Seam
Cover not completely seated on the Seaming Check Pin Height. Check Knockout Pad
Chuck adjustment. See 'Mismatch'
(Doubleseam.com. Wooling. Web)

Creasing
Creasing or sometimes called Scoring, is predominantly related to aluminum necked in beverage cans with reduced
cover diameters and will be visually seen around the outside diameter bottom edge of the Double Seam. Lithography
or aluminum will be scratched in part or all around the neck of the can. Sanitary cans also have the symptom. Creasing
will occasionally appear with small dents just below the cover hook radius where contact is made on the thin wall of
the neck.
Creasing. Digital Image. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016.

Figure 75: Creasing

2nd Operation Seaming Roll set too tight. Adjust 2nd Operation Seaming Rolls. Contact can
manufacture for specifications.
Can neck too short before angling or Discuss with Can Manufacturer
stepping out to the cans major diameter
Seaming Roll profile lower lip contacting Reduce the Seaming Roll profile lower lip or
can body replace the Seaming Roll with a Roll having a
more shallow profile groove
2nd Operation Roll incorrect for this Replace Seaming Rolls with Low Profile Seaming
application Rolls. Contact can manufacture for specifications
(Doubleseam.com. Creasing. Web)

Dissolved Oxygen (dO2) Testing
Oxygen trapped in the package contributes to flavor degradation in beer. The greater the amount of oxygen, the
greater the flavor degradation. The oxygen content of a package can be measured to determine if the origin of the
oxygen is from the headspace, or from the filling operation.
Beer consumes the oxygen in the package over time. In most beer, the majority of the oxygen is consumed over the
period of one week, but the flavor doesn’t change for two to three months. The oxygen consumption of packaged
beer can vary greatly, depending upon the storage temperature, type of beer and beer yeast content.
Sometimes the half-life can be a day and sometimes it is just a few minutes. Understanding how quickly your beer
reacts with oxygen will help you develop measurement protocols to allow for the most accurate measurements.
Oxygen is introduced into the package in three places: introduction of product to an improperly purged tank, during
filling, or in the headspace through incomplete fobbing. Oxygen can come from air already in the beer or from air
trapped in the can or filler tubes during filling. Headspace oxygen comes from air trapped in the headspace after the
end is applied. Because the partial pressures of gases in the headspace and the liquid are not at equilibrium immediately
after packaging, all packages should be shaken before measuring dissolved O2 (or N2 and CO2).
Typically, the largest concentration of oxygen is found dissolved in the beer. The following steps can be used to
determine whether the filler is the major contributor of oxygen. All measurements should be taken on unpasteurized
beer.
1. Check Brite tank dO2 levels.

2. Check filler bowl to ensure no pick-up prior to entering machine.
3. Pull five cans off of a moving filler that is free from starts and stops.
4. Measure three of the packages after shaking them for five minutes.
5. Measure two of the packages that have not been shaken.
6. Compare the dissolved O2 concentration of the average measurement from each group.
If the value goes up after shaking, the major source is in the headspace. If the value goes down, as is typical, the major
contribution is from the liquid. From this it can be determined if the filler is the source of greatest oxygen content.
(Hach, Web)

Combating Dissolved Oxygen (dO2)
A quality product deserves a quality fill. The Codi CCL-45 Counter Pressure filler achieves this by letting the user set
and adjust every step of the fill cycle through the HMI. The counter pressure fill process greatly reduces the potential
for oxygen pickup. This is done by ensuring that all oxygen is fully purged out of the can through adjustable purge
and snift cycles during filling. Once filled, dO2 is kept down with a bubble breaker and under lid gassing before the
can is seamed. If during testing for dO2 it is determined that the filler is the greatest source of oxygen content the
following aspects of the system should be evaluated.
1. Pre-Purge of Cans – Pre-purging of cans displaces the O2 trapped in the can with CO2 prior to product
entering the can. See details provided above on Pg. 20 for adjustments to evacuation cycles and flow through.
2. Fill Speed – Fill speed should be adjusted to control product flow into cans. See the Adjustments to Fill
Speed section provided above on Pg. 20 for details.
3. Snift – By controlling the snift and what pressure the seal is broken from the can post fill, the level of foam
on beer can be increased or decreased to help reduce dO2. See details provided above on Pg. 21 for making
adjustments to the snift.
4. Bubble Breaker – The bubble breaker helps in reducing dO2 in bubbles on top of the open cans. To see an
increase in the effectiveness of the bubble breaker reposition the bubble breaker, moving it farther away from
the filler and closer to the seamer. It is most effective to agitate a calmly filled product to create desired foam
on beer.
5. Underlid Gassing – Adjustments to the flow control for how much CO2 is coming out are made manually
at the under lid gasser by opening or closing the valve that is installed.
6. Product Slosh - Controlling product slosh in the can is critical to reducing dO2 in filled cans. Conveyor speed,
screw speed, and transfers are variables that impact slosh.
a. Conveyor Speed/Screw Speeds – Conveyor and screw speeds can be adjusted in the Speeds window
found on the Automatic Operation screen. See details for the Automatic Operation screen provided
below on Pg. 68.
b. Transfer – Ensure all transfer plates are properly aligned; they should sit just above the conveyor with
only enough space for a business card to fit in between the top of the conveyor and bottom of the
transfer plate. Ensure the transfer plates are clean as they can become sticky while running product
which will cause the cans to grab and tip.

CO2 Testing
The most common measurement technique for determining CO2 concentration in beverages is to measure the total
pressure and temperature of a sample. This method, known as the P/T method, involves measuring the total pressure
and temperature and then calculating the CO2 concentration in the liquid.
This method to determine the amount of CO2 is risky because it assumes that the only gas which is present in the
beverage is CO2, which is not the case. Air, in varying amounts, is always present.
The total pressure is actually due to the sum of all the partial pressures, as shown below.
ptotal ≠ pCO2
ptotal = pCO2 + pO2 + pN2 + pH2O
The amount of air changes depending on several factors, including source water temperature, incomplete de-aeration
and air contamination during production, filtering, and filling. Air doesn’t taste or feel like CO2. Most CO2 tables take
into consideration the amount of water vapor, shown here as PH2O. However, these tables do not consider the
amount of air, partial pressure of N2 and O2. Therefore the partial pressure of air contributes to the error in total
pressure measurements. Below is an example of how this error might not be visible using the P/T method in a typical
brewery:
Packages with low CO2 and high air (high dissolved O2 and N2) look identical to packages with target CO2 and low
air when using a P/T method; therefore the P/T method is not the best for ensuring CO2 quality and final product
consistency since the amount of air in the process changes from day to day.
Interference from air can be virtually eliminated using a volume expansion method. This method, known as the MVE
method, involves a system to fill a measurement chamber to measure the total pressure and temperature. The chamber
is expanded and the total pressure and temperature are measured again. The amount of CO2 is then calculated. This
method, however, uses a complex and delicate system that introduces the risk of mechanical failure and leaks, thereby
increasing the total cost of ownership. Additionally, the CO2 result is still a calculation and is based on total pressure
measurements.
An improved method to determine the actual CO2 in a beverage is to use thermal conductivity. This method, known
as TC, is ideal because specific gases can be measured with no influence from any other gases. Each gas has a different
thermal conductivity. (Klein/Robert, Web)

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The Handy-Dandy Slow Force Carbonation Chart featuring Pressure vs. Temperature in Degrees Fahrenheit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
30°F 1.82 1.92 2.03 2.14 2.23 2.36 2.48 2.60 2.70 2.82 2.93 3.02 3.13 3.24 3.35 3.46 3.57 3.67 3.78 3.89 4.00 4.11 4.22 4.33 4.44 4.66 4.77 4.87 4.98 4.98
31°F 1.78 1.88 2.00 2.10 2.20 2.31 2.42 2.54 2.65 2.76 2.86 2.96 3.07 3.17 2.28 3.39 3.50 3.60 3.71 3.82 3.93 4.03 4.14 4.25 4.35 4.46 4.57 4.68 4.78 4.89
32°F 1.75 1.85 1.95 2.05 2.15 2.27 2.38 2.48 2.59 2.70 2.80 2.90 3.00 3.11 3.21 3.31 3.42 3.52 3.63 3.73 3.84 3.94 4.04 4.15 4.25 4.36 4.46 4.57 4.67 4.77
33°F 1.71 1.81 1.91 2.01 2.10 2.23 2.33 2.43 2.53 2.63 2.74 2.84 2.96 3.06 3.15 3.25 3.35 3.46 3.56 3.66 3.76 3.87 3.97 4.07 4.18 4.28 4.38 4.48 4.59 4.69
34°F 1.68 1.78 1.86 1.97 2.06 2.18 2.28 2.38 2.48 2.58 2.69 2.79 2.90 3.00 3.09 3.19 3.29 3.39 3.49 3.59 3.69 3.79 3.90 4.00 4.10 4.20 4.30 4.40 4.50 4.60
35°F 1.63 1.73 1.83 1.93 2.02 2.14 2.24 2.34 2.43 2.52 2.63 2.73 2.83 2.93 3.02 3.12 3.22 3.32 3.42 3.52 3.62 3.72 3.82 3.92 4.01 4.11 4.21 4.31 4.41 4.51
36°F 1.60 1.69 1.79 1.88 1.98 2.09 2.19 2.29 2.38 2.47 2.57 2.67 2.77 2.86 2.96 3.05 3.15 3.24 3.34 3.43 3.53 3.63 3.72 3.82 3.92 4.01 4.11 4.21 4.30 4.40
37°F 1.55 1.65 1.74 1.84 1.94 2.04 2.14 2.24 2.33 2.42 2.52 2.62 2.71 2.80 2.90 3.00 3.09 3.18 3.27 3.37 3.46 3.56 3.65 3.75 3.84 3.94 4.03 4.13 4.22 4.32
38°F 1.52 1.61 1.71 1.80 1.90 2.00 2.10 2.20 2.29 2.38 2.48 2.57 2.66 2.75 2.85 2.94 3.03 3.12 3.21 3.30 3.40 3.49 3.59 3.68 3.77 3.87 3.96 4.06 4.15 4.24
39°F 1.49 1.58 1.67 1.77 1.86 1.96 2.06 2.15 2.25 2.34 2.43 2.52 2.61 2.70 2.80 2.89 2.98 3.07 3.16 3.25 3.34 3.44 3.53 3.62 3.71 3.81 3.90 3.99 4.08 4.18
40°F 1.47 1.56 1.65 1.74 1.83 1.92 2.01 2.10 2.20 2.30 2.39 2.47 2.56 2.65 2.75 2.84 2.93 3.01 3.10 3.19 3.28 3.37 3.46 3.55 3.64 3.73 3.82 3.91 4.01 4.10
41°F 1.43 1.52 1.61 1.70 1.79 1.88 1.97 2.06 2.16 2.25 2.34 2.43 2.52 2.60 2.70 2.79 2.88 2.96 3.05 3.14 3.23 3.32 3.41 3.50 3.59 3.68 3.77 3.86 3.95 4.04
42°F 1.39 1.48 1.57 1.66 1.75 1.85 1.94 2.02 2.12 2.21 2.30 2.39 2.48 2.56 2.65 2.74 2.83 2.91 3.00 3.09 3.18 3.26 3.35 3.44 3.53 3.62 3.70 3.79 3.88 3.97
43°F 1.37 1.46 1.54 1.63 1.72 1.81 1.90 1.99 2.08 2.17 2.26 2.34 2.43 2.52 2.61 2.69 2.78 2.86 2.95 3.04 3.13 3.21 3.30 3.39 3.47 3.56 3.65 3.74 3.82 3.91
44°F 1.35 1.43 1.52 1.60 1.69 1.78 1.87 1.95 2.04 2.13 2.22 2.30 2.39 2.47 2.56 2.64 2.73 2.81 2.90 2.99 3.07 3.10 3.24 3.33 3.41 3.50 3.58 3.67 3.76 3.84
45°F 1.32 1.41 1.49 1.58 1.66 1.75 1.84 1.91 2.00 2.08 2.17 2.26 2.34 2.42 2.51 2.60 2.69 2.77 2.86 2.94 3.02 3.11 3.19 3.28 3.36 3.45 3.53 3.62 3.70 3.79
46°F 1.28 1.37 1.45 1.54 1.62 1.71 1.80 1.88 1.96 2.04 2.13 2.22 2.30 2.38 2.47 2.55 2.64 2.72 2.81 2.89 2.98 3.06 3.15 3.23 3.31 3.40 3.48 3.57 3.65 3.74
47°F 1.26 1.34 1.42 1.51 1.59 1.68 1.76 1.84 1.92 2.00 2.09 2.18 2.26 2.34 2.42 2.50 2.59 2.67 2.76 2.84 2.93 3.02 3.09 3.18 3.26 3.35 3.43 3.51 3.60 3.68
48°F 1.23 1.31 1.39 1.48 1.56 1.65 1.73 1.81 1.89 1.96 2.05 2.14 2.22 2.30 2.38 2.46 2.54 2.62 2.71 2.79 2.88 2.96 3.04 3.13 3.21 3.30 3.38 3.46 3.54 3.63
49°F 1.21 1.29 1.37 1.45 1.53 1.62 1.70 1.79 1.86 1.93 2.01 2.10 2.18 2.25 2.34 2.42 2.50 2.58 2.67 2.75 2.83 2.91 3.00 3.07 3.15 3.23 3.31 3.39 3.47 3.56
50°F 1.18 1.26 1.34 1.42 1.50 1.59 1.66 1.74 1.82 1.90 1.98 2.06 2.14 2.21 2.30 2.38 2.46 2.54 2.62 2.70 2.78 2.86 2.94 3.02 3.10 3.17 3.25 3.33 3.41 3.49
51°F 1.18 1.26 1.34 1.42 1.49 1.57 1.64 1.71 1.79 1.87 1.95 2.02 2.10 2.18 2.26 2.34 2.42 2.49 2.57 2.65 2.74 2.82 2.90 2.97 3.05 3.13 3.19 3.27 3.34 3.42
52°F 1.16 1.23 1.31 1.39 1.46 1.54 1.61 1.68 1.76 1.84 1.92 1.99 2.06 2.14 2.22 2.30 2.38 2.45 2.53 2.61 2.68 2.76 2.84 2.92 3.00 3.06 3.13 3.22 3.30 3.37
53°F 1.14 1.21 1.29 1.36 1.44 1.51 1.59 1.66 1.74 1.81 1.89 1.96 2.03 2.10 2.18 2.26 2.34 2.41 2.49 2.57 2.64 2.71 2.79 2.86 2.94 3.01 3.09 3.16 3.24 3.31
54°F 1.12 1.19 1.27 1.34 1.41 1.49 1.56 1.63 1.71 1.78 1.86 1.93 2.00 2.07 2.15 2.22 2.30 2.37 2.45 2.52 2.59 2.66 2.74 2.81 2.89 2.96 3.04 3.10 3.17 3.24
55°F 1.10 1.17 1.24 1.31 1.39 1.46 1.53 1.60 1.68 1.75 1.82 1.89 1.97 2.04 2.12 2.18 2.26 2.33 2.40 2.47 2.54 2.62 2.69 2.76 2.83 2.89 2.97 3.04 3.11 3.18
56°F 1.07 1.15 1.22 1.29 1.36 1.43 1.50 1.57 1.65 1.72 1.79 1.86 1.93 2.00 2.08 2.15 2.22 2.29 2.36 2.43 2.50 2.57 2.64 2.71 2.78 2.85 2.92 2.99 3.06 3.13
57°F 1.05 1.12 1.19 1.26 1.33 1.40 1.47 1.54 1.62 1.70 1.77 1.83 1.90 1.97 2.04 2.11 2.18 2.25 2.32 2.39 2.46 2.53 2.60 2.66 2.73 2.80 2.87 2.94 3.00 3.08
58°F 1.03 1.10 1.17 1.24 1.30 1.37 1.44 1.51 1.59 1.67 1.74 1.80 1.87 1.94 2.01 2.08 2.15 2.21 2.28 2.35 2.42 2.48 2.55 2.62 2.69 2.75 2.82 2.88 2.95 3.02
59°F 1.02 1.09 1.16 1.22 1.29 1.36 1.43 1.49 1.56 1.64 1.71 1.77 1.84 1.91 1.98 2.04 2.11 2.17 2.24 2.31 2.38 2.43 2.50 2.57 2.64 2.70 2.77 2.84 2.91 2.97
60°F 1.01 1.08 1.15 1.21 1.28 1.34 1.41 1.47 1.54 1.62 1.62 1.75 1.82 1.88 1.95 2.01 2.08 2.14 2.21 2.27 2.34 2.40 2.47 2.53 2.60 2.66 2.73 2.79 2.86 2.92
61°F 0.99 1.05 1.12 1.18 1.24 1.31 1.37 1.44 1.50 1.57 1.63 1.69 1.76 1.82 1.89 1.95 2.02 2.08 2.14 2.21 2.27 2.34 2.40 2.47 2.53 2.59 2.66 2.72 2.79 2.85
62°F 0.96 1.02 1.09 1.15 1.21 1.27 1.34 1.40 1.46 1.52 1.59 1.65 1.71 1.78 1.84 1.90 1.97 2.03 2.09 2.15 2.22 2.28 2.34 2.41 2.47 2.53 2.59 2.66 2.72 2.78

63°F 0.93 0.99 1.06 1.12 1.18 1.24 1.30 1.36 1.42 1.49 1.55 1.61 1.67 1.73 1.79 1.85 1.92 1.98 2.04 2.10 2.16 2.22 2.28 2.35 2.41 2.47 2.53 2.59 2.65 2.71
64°F 0.91 0.97 1.03 1.09 1.15 1.21 1.27 1.33 1.39 1.45 1.51 1.57 1.63 1.69 1.75 1.81 1.87 1.93 1.99 2.05 2.11 2.17 2.23 2.29 2.35 1.41 2.47 2.52 2.58 2.64
65°F 0.88 0.94 1.00 1.06 1.11 1.17 1.23 1.29 1.35 1.41 1.46 1.52 1.58 1.64 1.70 1.76 1.82 1.87 1.93 1.99 2.05 2.11 2.17 2.23 2.28 2.34 2.40 2.46 2.52 2.58
Table Key:
Blue = Under-Carbonated, 0 – 1.40 volumes CO2
Gray = Stouts and porters, 1.50 – 2.20 volumes CO2
Green = Lagers, Ales, Ambers, most beers, 2.20 – 2.60 volumes CO2
Yellow = Highly carbonated ales, Lambics, Wheat beers 2.60 – 4.0 volumes CO2
Red = Over-carbonated (except for certain specialty ales) 4.1+ volumes CO2
* This chart is for use in force carbonating draft beer. Use this force carbonation chart at your own risk. Never exceed the pressure rating of the
carbonating vessel as injury to yourself or others may result. This information is provided "as is" and the author assumes no liability for the use of the
results from this force carbonation chart.
(Kegerators.com, Web)

HMI Defined
Common Buttons and Windows on All HMI Screens
The following section details the common buttons and windows that can be accessed through every screen of the
HMI. The location of these buttons is constant between each screen.
Figure 76: Common HMI Buttons & Windows
Icon/Field Title Description

Filling Paused/Pause When the system is running this button is used to
Filling Button pause and resume the filling process. It does not
pause/resume the seaming process.
Run One Cycle Used to run 5 cans through the machine and pause
Button when cycle is finished. Can be pressed at any point
during the fill process and the cycle will pause after
indexing the full cans.
Current Process A red box will indicate to the operator which auto
Indicator Window process is currently active.
Reset Drive Faults VFD faults that occur are reset with a push of this
Button button.
CCL-45 Tank Display for tank temperature, tank level, and tank
Window shown in grey background boxes. Setpoints for tank
level and tank pressure are shown in blue border
boxes.
Air & CO2 Inlet Indicates the main inlet pressure readings for
Window compressed air and CO2/Nitrogen (or other
working gas).
Initialize Screen When selected, takes you to the Initialize screen.
Button
Auto CIP Screen When selected, takes you to the Auto CIP screen.
Button
Manual Operation When selected, takes you to the Manual Operation
Screen Button screen.

Automatic Operation When selected, takes you to the Automatic
Screen Button Operation screen.
Setup Screen Button When selected, takes you to the Setup screen.
Recipes Screen When selected, takes you to the Recipes screen.

Button
Trends and I/O When selected, takes you to the Trends and I/O
Screen Button screen.
Alarms Button When selected, takes you to the Alarms screen.
Seamer Button When selected, takes you to the Seamer screen.
Initialize Screen
The Initialize Screen can be accessed at any time through the side menu by selecting the Initialize Button, highlighted
on the left hand side of Figure 77 below. After a few basic parameters are entered the CCL-45 can be run in Automatic
Mode from this screen.
Figure 77: Initialize Screen

Commonly Used See details provided above on Pg. 62.
Buttons and
Windows
Go To CIP Button Upon button press the CIP page will be displayed.
Initialization Press and hold for 1s to start/stop the initialization

Stopped/Running cycle.
Button
Step 1 Window When initialization starts, input pressure for tank to
pressurize to and number of tank purge cycles.

Step 2 Window When step 2 is active, click the recipe button to
jump to the recipe screen and select desired recipe.
Click back to the Initialize screen to continue and
verify tank pressure and tank level set points are as
desired.
Step 3 Window When step 3 is active, press the fill tank button
once all manual valves from supply tank to filler
bowl are open.
Auto CIP Screen

The Clean in Place Screen can be accessed at any time through the side menu by selecting the Auto CIP Button,
highlighted on the left hand side of Figure 78 below.
Figure 78: Clean in Place Screen

Buttons and
Windows
Auto CIP Press and hold for 1s to start/stop the auto CIP
Stopped/Running cycle.
Button
CIP Step 1 When the auto CIP cycle is active a button to start
step 1 will appear. Press to being filling tank.
CIP Step 2 When step 1 is complete, meaning the tank is 100%
filled and cleaning solution is pouring into the cans
and the cans are full, press button to start step 2.

CIP Auto Set the timer for desired amount of circulation time.
circulation duration This can be changed at any time during the cycle to
increase or decrease the duration, but cannot be
changed if step 2 was started and the timer was set
at 0 to begin with. At the end of the timer the
system will automatically move to step 3. At any
time the Start button for step 3 can be pressed.
CIP Auto Circulation time elapsed. Will not display if timer
circulation elapsed was set at 0 before starting step 2.
time
CIP Step 3 If step 2 is active, at any time the start button for
step 3 can be pressed to move system to step 3
instead of waiting for CIP Auto circulation duration
timer to finish.
Index 5 Cans When pressed the positioning screw will rotate 5
Button revolutions to index cans under the fill heads. The
fill heads must be up or this command will be
ignored.
Product Pump The Auto button shown allows the user to select
Window auto/manual operation of the pump. The Stopped
button is a start/stop for the pump when running
in manual mode, but also an indicator for the pump
running or not. Man. Set is the set point the pump
will run at ONLY when manual mode is selected.
The actual psi will display what psi is being applied
to the pump whether auto or manual is selected.
Valve open closed Valves that are open are displayed with a green box.
legend Valves that are closed are displayed with a white
box.
Valve open/closed Indicates whether the fill valves are open or closed.
indicators
Valve open/closed Indicates whether the tank to cans, tank to atm, fill
indicators throttles, or snift throttles are open or closed
Tank layout Shows visually where the tank is filled to and
displays fill level percent.
Gallons in tank Displays how many gallons are in the tank at any
moment in time.

Manual Operation Screen
The Manual Operation Screen can be accessed at any time through the side menu by selecting the Manual Operation
Button, highlighted on the left hand side of Figure 79 below. Once open each major component of the CCL-45 can
be manually ran independently from this screen. This is helpful at times when trying to resolve an alarm.
Figure 79: Manual Operation Screen

Buttons and
Windows
Fill Valve 1 Manual control to open/close fill valve 1
Window

Window

Window

Window

Window
All Fill Valves Select auto or manual control of fill valves and
Window manual control to open/close all fill valves.

Fill Heads Select auto or manual control of fill heads and
Window manual control of fill heads raised/lowered.
Tank to ATM Select auto or manual control of Tank to ATM and
Window manual control of Tank to ATM opened/closed.
Tank to Cans Select auto or manual control of Tank to Cans and
Window manual control of Tank to Cans opened/closed.
Seamer Lid Select auto or manual control of Seamer lid knife
Knife Window and manual control of seamer lid knife
extended/retracted.
Seamer Lift Select auto or manual control of Seamer Lift and
Window manual control of Seamer Lift raised/lowered.
Twist Rinse Select auto or manual control of Twist Rinse and
Window manual control of Twist Rinse opened/closed.
Bubble Break Select auto or manual control of Bubble Breaker and
Window manual control of Bubble Breaker opened/closed.
Underlid Gas Select auto or manual control of Underlid Gas and
Window manual control of Underlid Gas opened/closed.
Seamer Lid Push Select auto or manual control of Seamer Lid Push
and manual control of Seamer Lid Push
opened/closed.
CO2 to Cans Select auto or manual control of CO2 to Cans and
Window manual control of CO2 to Cans opened/closed.
Fill Throttle Select auto or manual control of Fill Throttles and
Window manual control of Fill Throttle open/closed set
point. Also the actual output to the valves is shown.
Snift Throttle Select auto or manual control of Snift Throttles and
Window manual control of Snift Throttle open/closed set
point. Also the actual output to the valves is shown.
Set All Manual Sets all controls to manual mode.
Button
Set All Auto Sets all controls to auto mode.
Button
button is a start/stop for the pump when running in
manual mode, but also an indicator for the pump

Conveyor Start and stop function for running the conveyor
Window and a set point for ft/min (speed). The actual speed
of the conveyor is also displayed.
Seamer Window Select auto or manual control or the Seamer Speed.

The seamer can only be set to auto when the filling
cycle is running. If in manual mode, the seamer will
use the Man. Set RPM set point when running. If in
auto mode, the seamer will use the set points on the
automatic run screen for belt speed and seamer
offset. This way the seamer speeds up and slows
down if the belt speed changes. The jog button
allows the user to jog the seamer as long as it is
depressed. The actual speed of the seamer is also
displayed.
Positioning When “Index 5 Cans” is pressed the positioning
Screw Window screw will rotate 5 revolutions to index cans under
the fill heads. The fill heads must be up or this
command will be ignored. The Jog+ and Jog-
buttons allow the user to align the cans under the fill
heads.
When the small Info Icon located in the Positioning Screw Window is selected the Drive Info/Status Window will
be displayed.
Once displayed, allows the operator to see current status of the conveyor, seamer, and positioning screw. Manual
adjustments can be made in the fields outlined in blue.
Figure 80: Drive Info/Status Window

Automatic Operation Screen
The Automatic Operation Screen can be accessed at any time through the side menu by selecting the Automatic
Operation Button, highlighted on the left hand side of Figure 81 below. After a few basic parameters are entered
the CCL-45 can be run in Automatic Mode from this screen.
Figure 81: Automatic Operation Screen

Buttons and
Windows
Start/Stop Filling Press and hold for 1s to start/stop the filling cycle.
Cycle “System”
Purge Window The two methods for purging the cans are shown
here. Choose how many cycles to run CO2 purge /
O2 evacuation to run or choose how long to purge
with CO2 while evacuating to ATM.
Flush/Evac Button Toggles between the two methods of purging
described above. Either Flush method or Evacuate.
Fill Window Set points to control the rate and duration of fill.
The duration of the fill can be controlled by time or
when the machine notices the cans are filled and the
pressures on each fill head begin to drop. The lower
the pressure drop, theoretically the lower the fill in
the can. A good starting point is 3. The throttle
controls the rate of fill. The higher the number the
faster product enters the can. A good starting point
is 3.5.
Snift 1 Window Controls how long the can head space is snifted
after filling. The throttle is a setpoint that will choke
the lines to slow the rate at which it snifts. The
higher the number the slower the snift rate.
Conveyor Press to start / stop the conveyor.
Start/Stop Button
Seamer Start/Stop Press to start / stop the seamer.
Button
ignored.
Speeds Window Set points for motor speeds. The conveyor speed
controls only the filler discharge conveyor. The
screw offset speed is the relative speed of the fill
index screw to the speed of the discharge conveyor
belt. The seamer offset speed is the relative speed
of the seamer with relation to the filler discharge
belt. In this way, speeding up and slowing down the
conveyor will also speed up / slow down the index
screw and seamer.
button is a start/stop for the pump when running
in manual mode, but also an indicator for the pump
Valve Indicators Box next to label indicates valve is open if green
and shut if grey.
The teach bubble breaker button can be pressed
and held to teach the bubble breaker when to be
open during the filling process.
Actual Can Displays the actual pressure in each can at any given
Pressures moment.
Containers Displays an estimated number of cans that can be
Remaining filled based on the remaining product in the tank.
Window The set point in ounces should be changed to what
size can is being filled for the most accurate
estimate.
Cans per Minute Displays the throughput in cans/min. This value is
Window updated every fill cycle based on the cycle time.

Setup Screen
The Setup Screen can be accessed at any time through the side menu by selecting the Setup Button, highlighted on
the left hand side of Figure 82 below.
Figure 82: Setup Screen

Buttons and
Windows
Purge Window The two methods for purging the cans are shown
here. Choose how many cycles to run CO2 purge /
O2 evacuation to run or choose how long to purge
with CO2 while evacuating to ATM.
Flush/Evac Button Toggles between the two methods of purging
described above. Either Flush method or Evacuate.
Fill Window Set points to control the rate and duration of fill.
The duration of the fill can be controlled by time or
when the machine notices the cans are filled and the
pressures on each fill head begin to drop. The lower
the pressure drop, theoretically the lower the fill in
the can. A good starting point is 3. The throttle
controls the rate of fill. The higher the number the
faster product enters the can. A good starting point
is 3.5.

Apply Default Sets all set points to Codi determined defaults.
Values Button
Goto Recipes Switches to recipe screen.
Button
Speeds Window Set points for motor speeds. The conveyor speed
controls only the filler discharge conveyor. The
screw offset speed is the relative speed of the fill
index screw to the speed of the discharge conveyor
belt. The seamer offset speed is the relative speed
of the seamer with relation to the filler discharge
belt. In this way, speeding up and slowing down the
conveyor will also speed up / slow down the index
screw and seamer.
Tank Pressure and Tank level and pressure set points to be applied
Level Window when system is running. These do not take effect
globally (set points at top of screen will not change)
unless or until the auto fill cycle system is running.
Auxiliary Window Choose whether or not the twist rinse valve opens
when the fill screw indexes. Set point for how long
the twist rinse stays open after index is complete.
Bubble breaker set point is the time that CO2 is
pushed to the bubble breaker after the fill heads
raise.
Positioning Screw When “Index 5 Cans” is pressed the positioning
Window screw will rotate 5 revolutions to index cans under
the fill heads. The fill heads must be up or this
command will be ignored. The Jog+ and Jog-
buttons allow the user to align the cans under the
fill heads. See Pg. 55 above for additional details on
the Positioning Screw Window.
Pump PI Values These PI values are used to control how the pump
Window responds to a difference between level set point and
actual during the filling process.
CO2 To Tank PI These PI values are used to control how the CO2
Values Window supplies the tank to pressurize it.
Pressure Units in Toggles global pressure units between PSI and

PSI Button BAR.

Temperature in ºF Toggles global temperature unit between °F and °C.
Button
Can Diameter Toggles seamer between different can diameters.
Window
Supply Tank For the operator only. These values are not used by
Window the system in any way. They are saved with recipes,
but they are designed as a place to note supply tank
product temp, pressure, carb volume and O2
volume.
Recipes Screen
The Recipes Screen can be accessed at any time through the side menu by selecting the Recipes Button, highlighted
on the left hand side of Figure 83 below.
Figure 83: Recipes Screen

Buttons and
Windows
Recipe Group Must select Filling Recipes.
Selection Window
Recipe Selection Choose which recipe to activate in the window.
Window
Load Button The active recipe values will be applied to the
system set points when this button is pressed.
Save Button The current values in the active recipe will be saved.
Snapshot Button A snap shot of the current system set points will be
applied to the active recipe. Values must be saved
before power cycle or they will be lost.
Compare Button Compares the active recipe to the current system set
points. If indicator turns green, recipe matches
active values. If yellow, they don’t match.
Delete Button Deletes the active recipe.
Active All Button Must select Filling Recipes.
Trends and I/O Screen

The Trends Screen can be accessed at any time through the side menu by selecting the Trends Button, highlighted
on the left hand side of Figure 84 below.
Figure 84: Trends Screen

Buttons and
Windows
Time selector Opens a calendar and clock selection to view
history of trends. Data is cleared through power
cycle.
Toggle to Air Toggles between trend graph showing Tank
Trends Button Pressure, Level, Temp, Cycle CPM, Avg CPM,
Lid Chute Jams and graph showing real time
data.
Real Time data Shows real time data of tank pressure, tank
Graph level, tank temp and cans/min.
Rewind Button Moves trend window back one second.

Pause Button Freezes trend window.
Play Button Moves trend window to live data.
Fast Forward Moves trend window forward one second.
Button
Input Indicators Indicates the status of the 4 inputs. Green
shows an input that is high/on and grey shows
an input that is low/off.
Real Time Data Legend
Graph Legend
Cans Filled/Cans Displays total cans filled and total cans seamed.
Seamed Window When cans reach correct pressure to fill, they
are added to the total cans filled. When the
system determines a can is to be lifted into the
chuck, it is added to the total cans seamed.

Alarms Screen
The Alarms Screen can be accessed at any time through the side menu by selecting the Alarms Button, highlighted
on the left hand side of Figure 85 below. The Alarms Screen catalogs all of the system faults that occur and allows
for them to be cleared once resolved.
Figure 85: Alarms Screen

Buttons and
Windows
Acknowledge All When selected, all active alarms are cleared.
Alarms Button
Acknowledge When selected, the current alarm highlighted
Selected Alarm in the Alarm History Window will be cleared.
Button
Row Up Button When selected, allows you to move up row by
row in the Alarm History Window.
Row Down When selected, allows you to move down row
Button by row in the Alarm History Window.
Page Up Button When selected, allows you to move up page
by page in the Alarm History Window.
Page Down When selected, allows you to move down
Button page by page in the Alarm History Window.
Active Alarm Displays any active alarms that are present in
Window the system.

Row Up Button When selected, allows you to move up row by
row in the Alarm History Window.
Row Down When selected, allows you to move down row
Button by row in the Alarm History Window.
Page Up Button When selected, allows you to move up page
by page in the Alarm History Window.
Page Down When selected, allows you to move down
Button page by page in the Alarm History Window.
Alarm History Catalogs all alarms that have occurred in the
Window machine providing a brief description, the time
the event occurred and the current status.
Coloring of the alarms indicates the following:
Red – Current active alarm requiring
resolution
Yellow – Alarm requires acknowledgement
Green – Prior alarm that has been cleared

Seamer Screen
The Seamer Screen can be accessed at any time through the side menu by pressing the Seamer Button, highlighted
on the left hand side of Figure 86 below. Once open you are enabled to make adjustments to different operations
within the SH-45 Single Head Seamer.
Figure 86: Seamer Screen

Buttons and
Windows
Can Diameter Toggles seamer between different can diameters.
Window

ignored.
Lid Jam Detect Toggle between lid jam detect active or inactive.
Active Button
Seamer Lid Knife Select auto or manual control of Seamer lid knife
Window and manual control of seamer lid knife
extended/retracted.
Seamer Lid Push Select auto or manual control of Seamer Lid Push
Window and manual control of Seamer Lid Push
opened/closed.

Seamer Lift Select auto or manual control of Seamer Lift and
Window manual control of Seamer Lift raised/lowered.
Seamer diagnostic Displays the seamer current index. Moves to next

readout index when encoder passes from 65535 to 0. Also
displays whether the system registered a can present
in shown index. The lift index is X number of
pockets behind the current index and is displayed.
Input indicators Indicates the status of the 4 inputs. Green shows an
input that is high/on and grey shows an input that
is low/off.
Conveyor Window Start and stop function for running the conveyor
and a set point for ft/min (speed). The actual speed
of the conveyor is also displayed.
Seamer Window Select auto or manual control or the Seamer Speed.

The seamer can only be set to auto when the filling
cycle is running. If in manual mode, the seamer will
use the Man. Set RPM set point when running. If in
auto mode, the seamer will use the set points on the
automatic run screen for belt speed and seamer
offset. This way the seamer speeds up and slows
down if the belt speed changes. The jog button
allows the user to jog the seamer as long as it is
depressed. The actual speed of the seamer is also
displayed.
Encoder Position Current seamer encoder position is displayed. To
Window adjust the encoder position, input desired value in
the blue border set point and press Apply Value and
hold for 1s. Current encoder position should
update.
Can At Lid Drop Jog to button will jog seamer at slow speed to very
Window near 19550 where the can at lid drop sensor should
be centered in a pocket.
Lid Screw Cutting Jog to button will jog seamer at slow speed to very
Window near 43275 where the separation point on the lid
separator should be beginning to separate the next
end from the stack.
Can At Dwell Start Jog to button will jog seamer at slow speed to very
Window near 33333 beginning of the dwell in the seamer
screw should be. Can should just be fully captured
in dwell.
Seam Op1 Start Jog to button will jog seamer at slow speed to very
Window near 38240 where the very beginning of the Seamer
Op1 roll is engaging. When timing the machine, this
set point should be set first.
Parts Detail - CCL-45 - Counter Pressure Filler
1
2
3
34
5
8
9
11
10
6
13
12
7
15
14
Figure 87: CCL-45 Parts Detail

16
17
Item Part Number Description

No.
1 CP007494 SUSPA JACK MOUNT, FILLER CART
2 Q4615 SUSPA MOVOTEC "Q" HANDCRANK HYDRAULIC PUMP, 1300LB SYSTEM, 4-LINE OUT
3 CP011567 BLAST SHIELD, FILL HEAD, BOLT ON FLANGE
4 98404A387 18-8 STAINLESS STEEL QUICK-RELEASE PIN, 3/8" DIAMETER, 2.7" USABLE LENGTH
5 CW000814 TWIST RINSE MOUNT WELDMENT, FILLER CART
6 CW003392 FRAME WELDMENT, FILLER CART, VERSION 4
7 30305T831 SAMSON CASTER SWVL, 6" X 2" RUBBER ON IRON WHEEL, 500LB CAP
8 CW003382 DRIP TRAY WELDMENT, FILLER, CROSS BREAK
9 CW003399 DRIP CATCH PAN WELDMENT, FILLER CART
10 CS001401 HMI ENCLOSURE SUB ASSEMBLY
11 CS001484 PNEUMATICS ENCLOSURE AND COMPONENTS ASSY
12 CS001509 TUBE MAP, ALUMINUM MANIFOLD, SUB ASSY, ANGLE SEAT VALVE UPDATE
13 CS000866 BUBBLE BREAKER, COUNTER PRESSURE INLINE FILLER
14 CA001639 DRIVE-TAIL ASSEMBLY, IN-LINE FILLER, 2 CONVEYORS, 73"LG.
15 PA233081 RNYMS02-1320YC-50 | SUMITOMO HYPONIC GEARMOTOR, 1320 FRAME, 1/4HP, 50:1, 1-1/4" SST
HOLLOW BORE, 230/460V, 3PH, 4 POLE, N34/N3C, CHEMI SHIELD 360 PACKAGE
16 CS000945 AIR AND CO2 INLET PREP SUB ASSEMBLY, MOBILE FILLER
17 CS001486 ELECTRICAL ENCLOSURE SUBASSEMBLY, 30" x 36" x 10", SHS, V4

Parts Detail - SH-45 - Single Head Seamer
Figure 88: SH-45 Parts Detail
Item Part Number Description

No.
1 87.7403392101 DRN80M4_FF_DH | SEW MOTOR, IEC FLANGE, 1HP, 4POLE, 60HZ 230/460V,
1700RPM, V3,3,X
2 CS001491 BELT IDLER, BOTTOM BELT, SINGLE HEAD SEAMER, 3"D
3 MB_3234 NEUGART PLANETARY GEARBOX, 32,1 RATIO, 070 FRAME, 19MM INPUT SHAFT,
16MM OUTPUT
4 CP015844 GATES SPROCKET, GT, 8MM PITCH, 20MM WIDTH, 30 TEETH, ELECTROLESS
NICKEL PLATED
5 CP013061 LID SCREW, SINGLE HEAD SEAMER, SINGLE SCREW CCW
6 UCFH206-20-SS-CEC REGAL BEARING, 1-1/4" BORE, TWO BOLT FLANGE, BLACK POLYAMIDE
HOUSING, SST INSERT, CLOSED END CAP
7 CS001490 BELT IDLER, TOP BELT, SINGLE HEAD SEAMER, SHORT, 3"D
8 CP015845 GATES SPROCKET, GT, 8MM PITCH, 20MM WIDTH, 22 TEETH, ELECTROLESS
NICKEL PLATED
9 1040-8MGT-20 GATES POWER GRIP TIMING BELT, GT2, 40.94" LONG, 20MM WIDE
10 800-8MGT-20 GATES POWER GRIP TIMING BELT, GT3, 31.5" LONG, 20MM WIDE
11 P22_8MGT_20 GATES SPROCKET, GT, 20MM, 22T, 108 BUSHING
12 CS001543 CHUCK AND ROLL SUBASSEMBLY, TAPPERED ROLLER BEARINGS, SINGLE HEAD
SEAMER

Maintenance
Observe the following notes before you start with inspection/maintenance work.
• Frequent observation of the canning system is recommended to detect problems. A change in sound of the
running system can be an indication of wearing parts.
• Disconnect the Canning System from the power supply before starting work to protect it against unintentional
re-start. Failure to do so could cause severe or fatal injuries.
• Let the motor cool down before you begin work. There is significant danger due to hot gears and hot gear
unit oil. Remove oil drain plugs slowly and carefully.
• Improper maintenance may result in damage to the Canning System or other property. Please contact Codi
Manufacturing prior to performing any maintenance not outlined in the below table.
Component/Manufacturer Time Interval What to Do

Chuck Shaft Bearing Block After Every Run • Charge with NLGI grade 2 consistency grease.
Bubble Breaker Subassembly After Every Run • Completely disassemble bubble breaker and clean all
components, soaking as necessary.
Under Lid Gassing After Every Run • Completely disassembly under lid gassing assembly
Subassembly and clean all components, soaking as necessary.
Gearboxes / Neugart MFG Commissioning & After • Perform visual inspection of seals at the input and
P/N WPLE080 & PLPE070 10 Hours of Run Time output for leaks.
• Listen for excessive noise during operation.
• Check temperature of gearbox.
• Check torque of motor and screw connections, to
include the motor shaft’s clamp.
Lid Separator, Lid Dropper Weekly • Perform visual inspection ensuring any debris or
and Lid Chute aluminum filings found are cleaned and removed.
Alignment Screws Monthly • Perform visual inspection of both screws.
• Thoroughly clean each screw using Scotch-Brite™
Light Cleansing Hand Pads (white in color).
Jack / Joyce-Dayton MFG Monthly • Charge with NLGI grade 1 consistency grease.
P/N: JD-WJ1000I4S-004.00-
STDX-STDX-X
Pin Height Monthly • Perform inspection with pin height gauge to ensure
setting is still within the allowed tolerance.
Spring Pressure Monthly • Perform inspection with spring pressure gauge to
ensure setting is still within the allowed tolerance.
Transfer Plates Monthly • Perform visual inspection ensuring coating on plate
still provides adequate coverage.
Seamer Lifter Plate/Cylinder Monthly /As Needed • Lubricate with 321 oil so lifter has free range of
movement.
Seaming Rolls Every 50k Cans • Charge with NLGI grade 0 consistency grease.
Mounted Ball Bearing Every 4 to 10 Months • Perform visual inspection of bearings.
Support / SYSTEM PLAST • Charge with 0.10oz of calcium sulfonate complex
MFG P/N: thickened grease with a NLGI grade 2 consistency.
UCFH206-20-SS-CEC

Pressure Transmitter / Every 6 Months • Visually inspect transmitter to ensure it is free from
Anderson-Negele MFG physical damage, moisture has not entered the
P/N: HH071G004A0A000 housing and that wiring is sound.
• Perform zero check calibration to ensure transmitter
is functioning properly.
Seamer Drive Belts / Gates Every 6 Months • Perform visual inspection of all drive belts. Look for
MFG P/Ns 1040-8MGT-20, cracking or fraying. Replace as needed.
800-8MGT-20 & 165L050
Fill Head Valve / GEA Annually • Replace all wear parts.
Mechanical MFG P/N:
HLA/P-OD3/4”/-MZ-
0000Z-1J/52/0
Pump / Tapflo MFG P/N Annually • Completely disassemble pump. Perform inspection
T80-STS on all components for wear. Replace as necessary.
Clean all components and reassemble.
Seamer Drive Motor / SEW Every 10,000 Hours • Check rolling bearing and change if necessary
Eurodrive MFG P/N • Replace the oil seal
DRN80M4_FF_DH • Clean cooling air ducts

Troubleshooting
OBSERVATION CAUSES CORRECTIVE ACTION
Filling
Short fills Pressure drop too low or Increase pressure drop value or fill timer depending on fill valve
Fill timer too short shut off method being used.
Float ball and claw Remove float ball and claw assembly from fill heads and remove
assembly too low shims from male shank as needed. Call Codi for spare parts.
Tank pressure inconsistent For best results, the tank pressure should reach the same pressure
value at the beginning of each fill cycle. If the tank is unable to
recover pressure fast enough, you may observe that every other
cycle (or so) is bad. In this case the CO2 supply needs to be
better. If this is not possible, the machine must be slowed down.
Recommend to add a settle time in the snift cycle (Snift time1 1-3
sec, throttle1 87 psi)
See observation: Too The machine will pour the beer into the cans with no foam since
foamy it’s under pressure, but the foam will reach the surface when the
fill heads raise. See causes for foaming below.
Over fills Pressure drop too high or Reduce pressure drop value or fill timer depending on fill valve
Fill timer too long shut off method being used.
Float ball and claw Remove float ball and claw assembly from fill heads and add
assembly too high shims to male shank as needed. Call Codi for spare parts.
Too foamy Tank pressure too low Tank pressure should be about 15-20psi above solubility pressure
chart
Fill Throttle (choke-psi) Filling too fast – CO2 is breaking out of solution when entering
too low can, bubbles are carried into can and those bubbles have to reach
the surface. This is foam
Pressure drop too high or The larger the pressure drop the machine needs to see to shut the
fill timer too long fill valves, the longer the valves stay open after the can is filled.
Over filling will cause unwanted foaming. Reduce pressure drop
(or fill timer, depending on what method is being used)
Total snift time too short Increase snift time. Can pressures are not low enough to lift fill
heads and prevent excessive foaming
Snift Throttle (choke-psi) If the final snift throttle is set too high, too much pressure will be
too high trapped in the can at the end of the fill and “shock” the product
when released to atmosphere.
Over filling See overfilling corrective action above.
Bubble breaker CO2 too The bubble breaker is designed to agitate a carbonated product
high and keep O2 out by creating some foam. If there is too much
CO2 dispensing, this can cause unwanted excessive foaming
Machine chooses Tank/Can Diff (psi) too Machine is looking for cans to reach a certain pressure. (Tank
not to fill certain low pressure – Tank/Can Diff (psi)) If any can does not reach this
cans pressure, the fill valve will not open.
Index screw misaligned Use HMI Jog+ and Jog- buttons to align fill heads with cans in
with fill heads index screw. Tip: always finish the adjustment with a Jog+ step as
there is too much hysteresis in the pockets of the screw to use
Jog- for alignment. Ensure that side rails keep cans tight in index
screw pockets.

CO2 supply weak If the machine is not receiving a sufficient supply of CO2, it will
not be able to pressurize the cans to the pre-fill set point. Notice
what pressure the CO2 inlet drops to when there is a large CO2
draw (increase tank pressure to see this in action) If the inlet
pressure drops very low and recovers very slowly, the CO2
supply is weak.
High Dissolved Tank not purged well Run initialize sequence before filling tank with product on next
Oxygen before filling process run
Cans not purged well Increase number of evacuate cycles OR increase flow through
before filling purge timer depending on which method is enabled.
Not enough foam Too much foam is bad, it will cause short fills or float lids in the
seamer, but not enough foam will allow lots of space for oxygen
to get it. Try the following.
• Reduce the snift time
• Increase final snift throttle
• Decrease fill throttle
• Decrease tank pressure
Not enough underlid gas Open the manual throttle valve to the underlid gas. You should
be able to hear it coming out of the gassing starwheel.
No product Air bubble is blocking flow Set pump to 35-40Hz and watch view port for air bubbles to pass
flowing into filler through system.
tank Input & output are Change “Press PSI” to a higher value. If the measured psi drops,
reversed the input & output are reversed.
Filler Can Handling
Cans being Inlet air pressure too high Adjust inlet regulator to between 95-100 psi
crushed by fill Air cylinder flow control Reduce flow from fill head cylinder lower port (turn flow control
heads at beginning set too fast or damaged knob right) If this doesn’t reduce cylinder speed, replace flow
of cycle control fitting.
Index screw misaligned Use HMI Jog+ and Jog- buttons to align fill heads with cans in
with fill heads index screw. Tip: always finish the adjustment with a Jog+ step as
there is too much hysteresis in the pockets of the screw to use
Jog- for alignment. Ensure that side rails keep cans tight in index
screw pockets.
Fill head stops set too low Set fill head stops so there is minimal over travel when sealing on
top of cans
Cans being Snift time is too long Adjust snift time down to leave some pressure (about 2 psi
crushed by fill minimum) in cans before fill heads lift
heads at end of Final snift throttle (choke- Adjust snift throttle up to prevent last few psi from leaving cans
cycle psi) is set too low before fill heads lift
Cans being Rails not set correctly Rails could either be set too far out or too far in. Ensure cans are
damaged by index snug in pockets of timing screw, but not being crushed at any
screw on infeed point.
Transfer plate set too high Lower transfer plate for cans indexing under fill heads
– cans likely tipping
Screw Off (ft/min) HMI Reduce the relative speed of the index screw to the conveyor. If
setting too high the screw is driving faster than the conveyor and there is not
sufficient back pressure, the cans will lean forward and the
transfer plate is harder to set this way.

Seamer
Lifter Lifting Too Feed screw timing off Retime screw to factory set points.
Soon Op1 timing off Encoder position needs adjusting.
Lifter Damaging Pin height set incorrectly Check pin height based on parameters listed on specification
Cans sheets received from end manufacturer. If set point from spec
sheet cannot be achieved contact Codi Manufacturing for
assistance.
Spring pressure too Verify pin height is set correctly. Verify spring pressure is set
high/low correctly and perform adjustments as needed per Spring Pressure
section on pg. 25.
Lifter is raising too quickly Adjust inline flow control valve at rear of machine.
Bad transfer/tipping cans Ensure transfer palates are clean. Polish the plates as necessary to
ensure a smooth transfer.
Ensure screw and guiderails are positioned correctly. Perform
adjustments as necessary.
Lifter Not Lifting Lifter is set in manual From manual run screen, ensure lifter is set to Auto.
mode
Issues with lid miss sensor Verify from seamer screen that lid missed sensor lamp is
triggering by manually raising the lid retention plate. If found,
contact Codi Manufacturing for technical support.
Cans Not Indexing Can is not engaged in Loosen the 5 mounting bolts and adjust screw accordingly until
Onto Lifter Pad pocket all the way maximum engagement is achieved.
Sticky transfer plate Ensure all foreign debris is cleaned off the transfer plate.
Perform visual inspection ensuring coating on plate still provides
adequate coverage. Replace if necessary.
Lids Not Being Feed screw timing off Retime screw to factory set points.
Dispensed Can detect sensor set Adjust positioning of sensor.
incorrectly
Low air pressure Check all lines and connections.
Lids Jamming At End chute block is Return to factory set point. If issues are still present contact Codi
Pusher misaligned Manufacturing for technical support.
End chute clogged with Perform visual inspection ensuring any debris or aluminum
debris filings found are cleaned and removed.
Lids Not Falling End chute clogged with Perform visual inspection ensuring any debris or aluminum
Down Lid Chute debris filings found are cleaned and removed.
Chute path too tight Loosen clamping bolts in effected areas to allow lid to travel
unimpeded.
Can and Lid Not Lid dropper height set Adjust overall height at the 3 height adjustment bolts. Perform
Mating Correctly incorrectly small adjustments and recheck.
Lid Separator Not Lid screw cutting timing Retime lid separator to factory set points.
Cutting off
Lid separator height to lid Ensure 0.020” gap from separator to track, perform small
track is off adjustments as necessary.
End chute block is Return to factory set point. If issues are still present contact Codi
misaligned Manufacturing for technical support.
Lid Separator Lid separator height to lid Ensure 0.020” gap from separator to track, perform small
Cutting Multiple track is off adjustments as necessary.
Ends End chute block is Return to factory set point. If issues are still present contact Codi
misaligned Manufacturing for technical support.
Lid Knocks Can Lid chute retention plate Clean retention plate of all debris. Ensure it moves freely. If issue
Over During movement impeded continues contact Codi Manufacturing for technical assistance.
Placement Guide rails improperly set Verify guiderails are set in such a fashion that can has proper
engagement in pocket.
Product Pump Low air pressure Check all lines and connections.
Freezing/Not Dirty/wet air supply Compressed air must be clean and dry in accordance with ISO
Turning On 8573-1:2010. If particles or water are found present in the air, the
warranty provided by Codi Manufacturing is VOID.
Internal components of Completely disassemble pump. Perform inspection on all
pump are dirty or worn components for wear. Replace as necessary. Clean all
components and reassemble.

Works Cited
• Doubleseam.com. A Finished Double Seam. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20
October 2016
• Doubleseam.com. Body Buckling. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Compound Squeezing. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October
2016
• Doubleseam.com. Creasing. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Damaged Cover Curl. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October
2016
• Doubleseam.com. Dead Head. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Droop. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. False Seam. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Hairpins. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Knocked Down Flange. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October
2016
• Doubleseam.com. Long Body Hook. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Long Cover Hook. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Long Seam Width. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Mismatch. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Mushroomed Flange. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October
2016
• Doubleseam.com. Seam Bumps. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Sharp Seam. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Short Body Hook. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Short Cover Hook. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October
2016
• Doubleseam.com. Short Seam Width. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Sprung Seam. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Vee. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20 October 2016
• Doubleseam.com. Visual Double Seam Defects. www.doubleseam.com. CMC-KUHNKE, Inc. Web. 20
October 2016
• Doubleseam.com. Wooling. www.doubleseam.com. CMC-KUHNKE, Inc. Web 20 October 2016
• Hach. How to Measure Dissolved Oxygen In The Brewery. www.hach.com. Hach. Web. 18 October 2016
• Kegerators.com. The Handy-Dandy Slow Force Carbonation Chart Featuring Pressure vs. Temperature in
Degrees Fahrenheit. www.kegerators.com. Kegerators.com. Web. 21 October 2016
• Klein, Chris. Robert, Elizabeth. Improved Method for CO2 Measurements. www.sachon.de. Verlag W.
Sachon. D-87714 Schloss MindleBurg. Web. 18 October 2016
• Rippen, Thomas E. Seafood Pasteurization and Minimal Processing Manual Sec 4 Pgs 77-79 & 85.
http://nsgl.gso.uri.edu. Virginia Cooperative Extension, Virginia Tech and Virginia State University. Web.
19 October 2016

Revision History
REV ISSUE DATE CHANGE LOG

A 12/06/17 Initial Release

Appendices
Appendix A: Neugart Planetary Gearbox P/N WPLE080 & PLPE070 Operating Manual

Appendix B: Joyce-Dayton Jack P/N JD-WJ1000I4S-004.00-STDX-STDX-X Technical
Data

Appendix C: System Plast Bearings P/N UCFH206-20-SS-CEC Data Sheet

Appendix D: Anderson-Negele Pressure Transmitter P/N HH071G004A0A000 Data Sheet

Appendix E: GEA Fill Head Valve P/N HLA/P-OD3/4”/-MZ-0000Z-1J/52/0 Technical
Data

Appendix F: Tapflo Pump P/N T80-STS Technical Data

Appendix G: SEW Drive Motor P/N DRN80M4_FF_DH Technical Data


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CRAFT CANNING SYSTEM - OWNERS MANUAL

CCL-45 - COUNTER PRESSURE FILLER

Technical Specification for Ideal Product and Filler/Seamer Operation ............................................................................ 5

Revision: A Codi Manufacturing, Inc.

Revision: A Codi Manufacturing, Inc.

Revision: A Codi Manufacturing, Inc.

Product Temp: 29-35°F

Counter Pressure Filler w/Seamer

Electrical Power Supply

208-240VAC 3 phase, 60Hz, 27A

Air Pressure Input: 100-110psi

Type of CO2: Beverage-Grade CO2

Supplemental CO2 Bottles: 50lb, Grade 3-A

Brewery Hose I.D. = 1-1/2” Tri-Clover Connection

Revision: A Codi Manufacturing, Inc.

Figure 1: CCL-45 with SH-45

Figure 2: CCL-45 with SH-45 Side View

Figure 3: CCL-45 with SH-45 Front View

Figure 4: Single Head Seamer Discharge Conveyor Rear Connection

Figure 5: SH Seamer Discharge Conveyor Dead Plate Alignment

Figure 6: Twist Rinse with Hand-fed Can Receiver

Figure 7: Twist Rinse Mount

Figure 8: Water Inlet & Outlet Valve on the Filler

Revision: A Codi Manufacturing, Inc.

Figure 9: Air & CO2 Panel

Figure 10: E-Stop Alarming

MASTER RESET RELAY BUTTON

Figure 12: Pneumatic Operations

Figure 13: Pos. Screw Window

Figure 14: CO2 To Cans Window - Off

Figure 15: Fill Heads Window

Figure 16: CO2 To Cans Window - On

Figure 17: Fill Valve Current Status

Figure 18: Filler Tank Status Window

Figure 19: Seamer Op1 Start Window

Figure 21: Lid Screw Cutting Window

Figure 23: Can At Dwell Start Window

Figure 25: Induction Sensor Placement

Revision: A Codi Manufacturing, Inc.

Figure 26: Recirculation Manifold Handle

Figure 27: Filler Tank Status Window

Figure 28: AUTO CIP Screen

Figure 29: CIP Step 1 - Start

Figure 30: CIP Step 2 - Start

Figure 31: CIP Step 2 - Running

Revision: A Codi Manufacturing, Inc.

Figure 32: CIP Step 3 - Running

Figure 33: Manual Operation Screen

Figure 34: Recirculation Manifold Handle

Figure 35: Initialize Screen

Revision: A Codi Manufacturing, Inc.

Figure 36: Initialization Step 1

Figure 37: Initialization Step 2

Figure 38: Initialization Step 3

Figure 39: Tank Empty Confirmation Window

Figure 40: Start Auto Fill Cycle Button

Figure 41: Auto Fill Cycle Confirmation Window

Revision: A Codi Manufacturing, Inc.

Figure 42: Automatic Operation Screen