Fill 1

Kosan Crisplant’s patented KCFiLL1 is the solution for filling small amounts of various sized gas cylinders in an economically sound way.

• • • • • Designed for easy, safe and accurate filling of LPG
        • Best value for money on the market for low-capacity filling machines
        • Able to fill any kind of cylinder
        • Can be installed anywhere you need

Get Started in no time

• KCFiLL1 is delivered ready for use inclusive of power supply, suspension chains, connection panel, LPG and air hoses, lifting device and filling head
• All that is required is a frame for suspension, supply of power, air and LPG
• KCFiLL1 is ready for data collection (optional)

Best solution for filling small amounts of cylinders

• Affordable price and low power consumption allows you to fill small volumes of cylinders
• No need to invest in a carousel or high capacity filling machine
• Just one KCFiLL1 and an operator and you are ready to fill

1-Step to create your own gas filling business

• Ideal means of releasing your entrepreneurial potential
• Affordable price allows you to establish you own gas filling business at a low cost without compromising your safety
• Designed according to Kosan Crisplant’s high standards, KCFiLL1 is safe and easy to operate, even for those without prior experience with LPG filling

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Spare Parts

Original Kosan Crisplant spare parts for filling equipment ensure long service life and continuous high production.

• • • • • Spare parts in compliance with original equipment standards
        • Scheduled replacement of spare parts leads to high reliability in operation
        • Spare parts in stock ensure immediate repair
        • Kosan Crisplant’s stock handling system provides full overview

Purging Systems

Kosan Crisplant’s purging systems are designed for quick and safe replacement of atmospheric air in cylinders with LPG in vapour state.  The process is applied on LPG cylinders without valves.  Valves should be mounted right after the purging process.

• • • • • Avoid dangerous mix of LPG and atmospheric air in cylinders
        • Filling speed at maximum level
        • Avoid capacity reduction
        • Controlled process: no dangerous aeration of cylinders after filling
        • No aeration of cylinders when end-users start using them

Your Benefits

• High safety for end-users
• Easy to use purging unit
• The manual purging unit requires minimum space
• Minimum maintenance
• Flexible to all cylinder diameters and heights
• Easy installation in existing plants

Your Possibilities

• Manual, semi-automatic or fully automatic process
• Manual purging unit can be used as stand-alone unit or together with conveyor
• Dosing of variable quantity of LPG depending of cylinder size
• Vacuum suction and / or gas dosing
• Automatics for control of cylinder flow with manual purging unit in-line in chain conveyor

Your Safety

• All purging systems are EU approved and designed in accordance with current EU directives, including the ATEX Directive (94/9/EC)
• All purging systems are designed for use in hazardous areas classified as Zone 1 according to IEC 79-10 and Class I, Division 1 according to NEC (USA), article 500
• National / local approvals

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Pressure Testing Equipment

Kosan Crisplant’s pressure testing equipment is designed for rapid and safe pressure testing of LPG cylinders.  Pressure testing is a part of the general requalifiction and testing procedure.

• • • • • Pressure tested cylinders are safe cylinders
        • Flexible solutions which meet any requirement
        • High capacity up to 450 cylinders per hour
        • Variable test pressure up to 45 bar

Your Benefits

• Stand-alone racks can be installed directly in the filling hall
• Visual inspection of the total cylinder surface
• Recirculation of water means low water consumption
• The test period can be varied
• High safety thanks to the use of water as pressure medium
• High filling / evacuation speed

 Your Possibilities

• Carousel system with up to 20 pressure testing units for domestic cylinders
• Pressure testing unit for carousel with manual or automatic horizontal rotation
• Pressure testing unit for carousel for one cylinder size or manually height adjustable
• Stand-alone pressure testing rack for 5 to 10 domestic cylinders
• Sand-alone pressure testing rack for one cylinder size, or manually height adjustable for industrial cylinders and domestic cylinders
• Pump unit (low pressure / high pressure pump) including water tank with a volume of 1,000 or 2,000 litres
• Corousel solution with integrated pump unit and water tank
• Pressure test heads with integrated immersion pipe
• Immersions pipes for all cylinder flange types

 Your Safety

• All pressure testing equipment is EU approved and designed in accordance with current EU directives
• National / local approvals

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Internal Cleaning and Inspection Equipment

With Kosan Crisplant’s equipment for internal cleaning and inspection of LPG cylinders you can perform efficient cleaning of LPG cylinders as well as visual control of the state of LPG cylinders after cleaning.

• • • • • Internal cleaning and inspection of LPG cylinders in part of the requalification procedure
        • Requalification of LPG cylinders is important because of the cylinder’s high value
        • Internal cleaning  and inspection of LPG cylinders is easy to perform while changing valve
        • Internal cleaning of cylinders contributes to high safety
        • Cylinders with long life cycle

Your Benefits

• When cylinders are cleaned internally, the water used during the pressure testing process is clean
• Residue emptying device removes bad smelling slurry from cylinders
• Efficient high pressure cleaning with rotating nozzle
• Only little water is consumed during internal cylinder cleaning process
• Collection of slurry in closed container prevents obnoxious smells and environmental pollution

 Your possibilities

• Fully automatic cleaning equipment for installation in-line in chain conveyor
• Cleaning equipment can be supplied with pump unit and water tank
• Fully automatic water and slurry emptying device for installation in-line in chain conveyor
• Manual residue emptying device for installation in-line in chain conveyor or as stand alone unit
• Cleaning equipment and emptying device with 1,000 litre water tank with filter and pump unit
• Video equipment or simple inspection equipment with light source for manual internal cylinder inspection. 

Filling Heads

Kosan Crisplant’s filling heads are designed for safe and easy filling and evacuation of all types of LPG cylinders.

• • • • • High quality and solid systems developed on the basis of 50 years’ experience
        • Operation can be fully automatic, semi-automatic or manual
        • Optimised flow and filling speed
        • High safety level
        • Can be used for both filling and evacuation

Your Benefits

• Lasting quality
• Easy and fast coupling and decoupling
• Minimum gas discharge at coupling and decoupling
• No gas discharge at sudden interruptions in compressed air supply
• Manual and semi-automatic filling heads are operated by single hand
• Flexible suspension for coupling of valves which are not in central position for filling
• Ergonomic operation of manual and semi-automatic filling heads thanks to balanced suspension
• Minimum maintenance

 Your possibilities

• Filling heads for all types of centre valves and screw valves
• Customer specific filling heads for special valves
• Coupling and decoupling can be manual, semi-automatic for fully automatic
• Usage in combination with a large variety of filling machines

 Your Safety

• All filling heads are EU approved and designed in accordance with current EU directives,  including the ATEX Directive (94/9/EC)
• All filling heads are designed for use in hazardous areas classified as Zone 1 according to IEC 79-10 and Class I, Division 1 according to NEC (USA), article 500.

UFM Universal Filling Machine

Kosan Crisplant’s reliable, tried and tested Universal Filling Machine.  Includes:

• • • • • Most used filling machine in the world
        • Weighing principle (load cell) or mass flow principle.
        • Operation; fully automatic, semi-automatic or manual.
        • Installation: On carousel, in-line in conveyor, or as stand-alone unit.
        • Competitive price

Your Benefits

• Satisfied end-users due to accurately filled cylinders
• Savings on LPG because of high filling accuracy and intelligent filling software
• Low installation costs due to intrinsically safe system
• Minimum maintenance and service requirements
• Low power consumption
• Easy and safe to operate
• High safety due to intrinsically safe system
• Easy adjustment and maintenance (error messages in display)
• Ready for integration in filling system network
• Ready for communication with PC for data collection

 Your Possibilities

• Corousel models for high capacity batch filling (from approximately 300 cylinders per hour) and/or for automated filling. 

Manual Leak Detectors

Kosan Crisplant’s manual leak detectors are designed for manual leak detection on valve seats of LPG cylinder valves.  Includes:

• • • • • Leak detection on the basis of visual inspection
        • Ideal solution for low capacity filling plants
        • Suitable after random filling of different cylinder types
        • Easy installation in existing plants
        • Small investment

Benefits

• Easy to use
• Hand-held and mobile units
• Minimum maintenance
• Minimum space requirements
• Flexible to all cylinder diameters and heights

Possibilities

• Manual leak detectors for centre valves or screw valves
• Practical gallows suspension can be supplied
• Can be used as stand-alone unit or together with conveyor
• Automatics for control of cylinder flow at in-line chain conveyor

Safety

• All manual leak detectors are designed for use in hazardous areas classified as Zone 1 according to IEC 79-10 and Class I, Division 1 according to NEC (USA), article 500
• National/local approvals

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Electronic Leak Detectors and Valve Testers

Kosan Crisplant’s electronic leak detectors and valve testers perform tests on LPG cylinder valves. The cylinders are approved or rejected according to preset permitted values.  Includes:

• • • • • Provide maximum safety
        • Fully automatic test with same sorting limit
        • Eliminate human errors
        • Detect all kinds of leak around the valve
        • Check the valve form (centre valves only)
        • Flexible for all types of valves
        • Flexible for all cylinder diameters and heights
        • Easy installation in existing plants
        • Minimum space requirements
        • Competitive price

Benefits

• Safe LPG cylinders to your end-users
• 100% leak test – all filled LPG cylinders are tested
• Savings on manpower thanks to automatic sorting of cylinders with unapproved valves
• Easy to use calibration tools and procedure
• Easy adjustment and maintenance
• Low power consumption
• Air service unit with extra filters to eliminate pollution in pneumatic air supply
• Minimum maintenance
• Easy to set up: all necessary software is installed in the HMI/CUC controller
• Easy to use: clear text display and sturdy keyboard
• Ready for integration in fully automatic filling system
• Ready for communication with PC for data collection

Possibilities

• Test heads designed for all types of valves
• Testing principle according to valve type and testing area on valve: gas analysis principle (leak detectors) or pressure rise principle (valve testers)
• Manually operated model for installation (1) stationary on floor, (2) by a chain conveyor or (3) by a roller conveyor.

Check-Weighing Systems

Kosan Crisplant’s check weighing systems are specifically designed to ensure accurate and quick control of the net content in LPG cylinders. The systems are designed to ensure correctly filled cylinders every time.  Includes:

• • • • • Safe cylinders to your end-users
        • Automatic sort-out of under- and overfilled cylinders
        • Capacity up to 1,800 cylinders per hour
        • Flexible for all cylinder diameters and heights
        • Easy installation in existing plants
        • Competitive price

Benefits

• Check weighing of all filled LPG cylinders
• Automatic sort-out of under- and overfilled cylinders saves manpower and eliminates human errors
• High safety due to intrinsically safe network
• Easy and safe operation
• Easy calibration and zero-setting
• Minimum maintenance and service requirements
• Easy adjustment and maintenance
• Ready for integration in filling system network
• Ready for communication with PC for data collection
• Low installation costs

Possibilities

• Fully automatic, semi-automatic or manual operation
• Check weighing system in-line in chain conveyor with lifting table for stationary check weighing or with dynamic weighing table for continuous check weighing
• Check weighing system in-line in chain conveyor for fully automatic check weighing with automatic transfer of tare weight from central encoding station
• Check weighing system in-line in chain conveyor for semi-automatic check weighing with manual encoding of tare weight
• Check weighing system in-line in chain conveyor for semi-automatic check weighing with tare compare carried out by operator
• Stationary check scale for installation on floor

Safety

• All check weighing systems are EU approved and designed in accordance with current EU directives EN 50014, EN 50020, EN 50081, EN 50082, EN 55022, incl.