Operation & Filling

RAPT Can & Bottle Filler | Operation & Filling Guide

When not in use disconnect the RAPT Can and Bottle Filler from the gas supply to prevent the risk of gas leaking to atmosphere

When not in use disconnect the power supply, clean the liquid and gas tubes out thoroughly to prevent mould

Only use 24V power supply that comes with the unit. DO NOT attempt to use other power supplies that are rated to a different voltage

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How the Unit Measures Fill Levels

The RAPT Can & Bottle Filler uses advanced pressure sensing to determine the fill level.

The device measures the back-pressure inside the gas purge tube. As liquid rises in the vessel, it creates a specific pressure change within the tube. The RAPT software calculates this pressure in real-time to determine the exact height of the liquid, ensuring a consistent fill height every time, regardless of the vessel shape.

Units of measurement - RAPT Can & Bottle Filler

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Fill Presets

The RAPT Can & Bottle Filler comes with pre-defined Fill Presets stored in the system. These can be accessed through the on-screen menu to select the vessel type best suited to your current application.

When first setting up your unit, we recommend adjusting these presets to match your specific cans or bottles perfectly.

Manual Presets

Manual presets are the quickest way to calibrate a fill level. This is done by measuring the distance between the bottom of the gas purge tube and the desired fill line (the top of the container).

1. Position the vessel: Place the container you intend to fill into the fill position.

2. Mark the fill line: On the gas fill tube, mark the point where you want the unit to stop filling (typically the top of the can/bottle).

3. Measure: Measure the distance from the bottom of the gas purge tube to the mark you just made.

4. Edit Preset: On the device, navigate to:

   Menu > Fill Presets > [Select the Preset to Edit]

5. Adjust Height: Select Fill Height and press Select .

6. Save: Input your measurement and press Enter to save.

Automatic Presets

Automatic presets offer a more precise calibration, especially useful for bottles where liquid displacement needs to be taken into account for an exact headspace.

Note: System Calibration must be completed before creating automatic presets.

1. Purge the line: Navigate to Menu > Manual Fill. Hold the Up and Down simultaneously to purge the gas line.

2. Pre-fill: Manually fill your container to your exact desired level (account for the volume that will remain once the filler is removed).

3. Position: Place this pre-filled container into the fill position.

4. Edit Preset: Navigate to:

   Menu > Fill Presets > [Select the Preset to Edit]

5. Select Height: Select Fill Height and press Select .

6. Auto-Calibrate: Press the FILL button (the button with the green light). The unit will automatically detect the fill height.

7. Save: Press Select to save the new height to the preset.

Offsets

"On-the-Fly" Adjustments

If you need to make a minor adjustment during a production run without changing your permanent settings, use the Up or Down buttons on the display to adjust the Offset.

• When to use: Use this if the purge tube is accidentally moved or if environmental factors are causing slight fill variations.

• Important: Offset values are temporary. If you find a preset is consistently over-filling or under-filling, you should permanently update the measurement in the Fill Presets menu.

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Minimising Foaming

If you are experiencing excessive foam, check these three factors:

1. Tube Depth: Ensure the stainless fill tubes reach the bottom of your vessel.

   • Adjustment A: Slide the stainless tubes up or down within their clips.

   • Adjustment B: Loosen the wing nuts on the side of the unit to raise or lower the entire platform.

1. Temperature: Keep your keg as cold as possible (0°C – 2°C) without freezing. Warm liquid releases CO₂ much faster. Purge the line of warm liquid prior to a packaging run.

2. Line Length: Ensure you have adequate liquid line length (typically 1.5m to 3m of 4mm ID beer line) between your keg and the RAPT filler. This creates "line resistance," which naturally slows the liquid down before it reaches the vessel. If you see large bubbles forming the moment the liquid hits the bottom of the can, your flow is too fast.

3. Pressure Management: Reduce your dispensing pressure at the keg regulator to the minimum required to move the liquid. Always remember to purge the keg headspace after dropping the pressure.

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Filling process

1

Sanitise the System

To ensure your beverage remains shelf-stable, always sanitise the unit before use.

• Internals: Run a sanitizer solution (we recommend StellarSan) through the liquid lines, tubes, and connections.

• Externals: Spray the exterior of the fill and purge tubes with a surface sanitizer (we recommend Super Kill Ethyl-Sanitizer).

• Contact Time: Allow at least 2 minutes of contact time with StellarSan before proceeding.

2

Connect the Beverage & Gas

• Beverage: Connect your transfer line from the Yellow Carbonation Cap to the pressure vessel (keg) or pump.

• Gas: Connect your CO2 gas line to the Red Carbonation Cap on the unit.

3

Purge & Prime the Lines

Before filling your first vessel, you must clear the sanitiser and "prime" the system with your beverage.

• Press and hold the Pinch Valve button manually.

• Run the beverage through until the lines are fully primed with the filling liquid.

This also pre-chills the lines and stainless fill tubes, which is essential for minimising foam on your very first fill.

4

Select Your Fill Preset

• Press the Cycle/Back button until the preset name at the top of the screen is highlighted.

• Use the Up or Down buttons to scroll through your saved presets.

• Stop when your desired vessel profile is displayed.

5

Start the Fill Cycle

Place your vessel in the fill position and press the FILL button (the one with the green light). The unit will automatically execute the following sequence:

[Purge] > [Wait] > [Filling]

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Production Monitoring Terms

• Fill Count: The total number of successful fills completed during the current session.

• CPM (Cans Per Minute): Your real-time production speed, calculated based on the frequency of completed fills.

• AFT (Average Fill Time): The average duration (in seconds) required to complete a single fill cycle during the current session.

How to Reset Data

If you wish to clear these figures (e.g., when starting a new batch or changing vessel sizes):

1. Use the menu to hover over the specific figure you wish to reset.

2. Hold down either the Up or Down button for 3 seconds.

3. The value will return to zero.

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